1996 LAND ROVER DEFENDER radio

76CHASSIS AND BODY
24
REPAIR CUBBY BOX - 90/110 STATION WAGON
Service repair no - 76.25.04
Remove
1.Remove radio/cassette player, if fitted.
2.Open cubby box lid and remove 2 caps
concealing fixing bolts.
3.Remove fixing bolts and washers.
4.Remove 2 screws and lift cup holder from cubby
box.
5.Unscrew 2 bolts securing front of cubby box to
floor mounting.
6.Lift cubby box and, if applicable, release
radio/cassette player leads.
7.If fitted, disconnect multi-plug from EGR control
unit, located on base of cubby box.
8.Remove cubby box.
Refit
9.Position cubby box to mounting and, if
applicable, insert radio/ cassette player leads.
10.Secure front of cubby box to floor and fit cup
holder.
11.Open cubby box lid, secure in position, and fit
bolt caps.
12.Fit radio/cassette player, if fitted.REAR GRAB HANDLE - 90/110 STATION WAGON
Service repair no - 76.58.35
Remove
1.Carefully prise top and bottom edges of finisher
caps from grab handle and then hinge outwards
to gain access to fixing screws.
2.Remove 4 fixing screws and detach grab handle
from rear end trim panel.
Refit
3.Position grab handle on rear end trim panel and
secure with 4 fixing screws.
4.Press finisher caps over screws.

76CHASSIS AND BODY
34
REPAIRREV: 05/99 LOWER FASCIA PANEL (HEATER DUCT)
ASSEMBLY
Service repair no - 76.46.05
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel
.
3.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle
.
4.Remove instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
5.Release heater cable at control lever
See
HEATING AND VENTILATION, Repair, Heater
control cable - air distribution
.
6.Remove 2 screws, withdraw switch panel from
lower fascia and disconnect switch multi-plugs.
7.Prise out Land Rover decal and remove screw
securing grab handle to crash pad.
8.Remove lower screw and lift grab handle from
lower fascia panel.
9.On RH drive vehicles only, remove screw
securing LH side of finisher to wiper motor cover.
10.Remove 4 screws and remove both demister
vents from crash pad.
11.Remove 3 screws securing crash pad to fascia
bulkhead.
12.Remove crash pad.
13.Remove radio, if fitted.
14.Remove 2 trim studs securing radio housing to
trim panel. Remove radio housing.

CHASSIS AND BODY
35
REPAIR REV: 05/99
15.If fitted, remove 2 screws, washers and nuts
securing auxiliary switch panel to lower fascia
panel and switch cover.
16.Withdraw switch panel and disconnect switch
leads.
17.Remove 2 screws securing switch cover to
parcel tray.
18.Remove fuse box cover.
19. Models with hand throttle:
Remove fuse box LH retaining screw.
Pivot fuse box down to gain access to lower
inner hand throttle cover fixing screw.
Remove 4 screws and lift up hand throttle cover
from lower fascia panel.
20.Remove 2 screws and remove both footwell
vents from lower fascia panel.
21.Remove single screw and detach door check
strap cover from LH and RH doors.
22.Remove 3 screws securing wiper motor cover to
fascia bulkhead.
23.Release locating pins from fascia panel, lower
wiper motor cover and, if applicable, disconnect
radio speaker leads. Retain wiper motor rack
cover. On LH drive vehicles, disconnect
multi-plugs from rear of switch panel.
24.Prise out 2 large and 5 small cap fasteners
securing trim panel to parcel shelf and fascia
bulkhead.
25.Carefully fold back trim panel to clear fresh air
vent operating levers and remove panel from
parcel shelf.

76CHASSIS AND BODY
36
REPAIRREV: 05/99 26.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
27.Remove parcel shelf.
28.Remove 7 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates.
29.Remove both retaining plates and lower footwell
covers.
30.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
31.With assistance, lower fascia panel and, if
applicable, disconnect RH radio speaker leads.
32.Remove fascia panel from vehicle.Refit
33.Position lower fascia panel to bulkhead,
reconnect RH speaker leads, if applicable, and
secure top edge with 2 bolts.
34.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
35.Repeat operation for LH footwell cover retaining
plate.
36.Fit remaining lower fascia panel fixing screws.
37.Locate parcel shelf. Ensure all radio and
auxiliary switch panel harness leads and plugs
are fed through aperture in parcel shelf.
38.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
39.Fit trim panel and secure with cap fasteners.
40.Reconnect LH speaker leads, if applicable,
locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated. On LH drive
vehicles, reconnect multi-plugs to rear of switch
panel.
41.Secure finisher to wiper motor cover.
42.Fit door check strap covers on both sides.
43.Fit footwell vents to lower fascia panel.
44. Models fitted with hand throttle:
Fit hand throttle cover.
Secure LH side of fuse box.
45.Fit fuse box cover.
46.Fit auxiliary switch cover to parcel tray, if
applicable.

CHASSIS AND BODY
37
REPAIR REV: 05/9947.Connect leads and plugs to auxiliary switches
and clock.
48.Secure switch panel to lower fascia panel and
switch cover.
49.Position radio housing, if applicable, and feed
radio multi- plug, aerial and speaker leads from
switch cover to radio housing.
50.Secure radio housing to trim panel.
51.Fit radio connections and secure radio in
housing.
52.Fit crash pad to fascia bulkhead.
53.Fit demister vents in crash pad.
54.Fit grab handle to lower fascia panel and secure
to crash pad. Refit Land Rover decal.
55.Connect multi-plugs to rear screen, hazard and
interior lamp switches and fit switch panel to
fascia panel.
56.Fit heater control cable
See HEATING AND
VENTILATION, Repair, Heater control cable -
air distribution
.
57.Fit instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
58.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle
.
59.Fit steering wheel
See STEERING, Repair,
Steering wheel
.
60.Reconnect battery.FRONT UNDERTRAY
Service repair no - 76.11.81 - Front undertray
Service repair no - 76.11.85 - Acoustic pad
Remove
1.Raise vehicle on ramp.
2.Position support under chassis front
crossmember.
3.Lower ramp to give clearance between axle and
undertray.
4.Remove 4 nuts, disconnect propeller shaft from
front axle, and move aside.
5.Remove 2 bolts securing undertray to chassis
front crossmember.
6.Remove nut securing undertray to bump stop
front fixing bolt on both sides.
7.Remove 2 bolts securing sides of undertray to
rear undertray.
8.Pull front undertray forwards to release flanges
from rear undertray.
9.Lower undertray to clear steering box etc. and
manouvre rearwards over axle.
10.Remove front undertray.
11.If necessary, remove 8 fasteners to release
acoustic pad from undertray.

WIPERS AND WASHERS
1
REPAIR WIPER MOTOR AND DRIVE RACK
Service repair no - 84.15.09
Remove
1.Disconnect battery.
2.Remove wiper arms.
NOTE: Operations 3 - 5 are for RH drive
vehicles only.
3.Prise Land Rover decal from grab handle and
remove screw.
4.Remove lower screw and lift handle from fascia.
5.Remove screw fixing finisher to wiper motor
cover.
6.Remove door check strap cover, remove 3
screws and withdraw wiper motor cover. If
applicable, disconnect switch multi-plugs and/or
radio speaker leads.
7.Disconnect multi-plug from wiper motor.
8.Disconnect wiper motor earth lead. (Not
applicable on later models)
9.Lift rubber sleeve and slacken wiper motor to
drive tube nut.
10.Remove 2 screws and release wiper motor
retaining strap.
11.Fully unscrew tube nut.
12.Pull wiper motor and drive rack clear of tube and
retrieve mounting pad and earth tag.
Refit
13.Feed wiper motor drive rack into tube until fully
seated.
14.Loosely fit drive tube securing nut.
15.Fit wiper motor securing strap, earth tag and
mounting pad. Align motor and tighten fixing
screws.

84WIPERS AND WASHERS
4
REPAIR
9.Remove door check strap cover and 3 screws
and withdraw wiper motor cover. If applicable,
disconnect switch multi-plugs and/or radio
speaker leads.
10.Disconnect wiper motor multi-plug.
11.Disconnect earth lead. (Not applicable on later
models)
12.Lift rubber sleeve from wiper motor and slacken
wiper motor to drive tube nut.
13.Remove 2 screws and release wiper motor
retaining strap, complete with mounting pad and
earth tag.
14.Pull wiper motor and drive rack clear of drive
tubes.Refit
15.Feed drive rack into drive tube until fully located
in wheel boxes.
16.Finger tighten drive tube nut.
17.Position motor mounting pad, fit retaining strap,
including earth tag and secure wiper motor
assembly.
18.Fully tighten drive tube nut and fit rubber sleeve.
19.Fit wiper motor multi-plug and earth lead to tag
on motor retaining strap.
20.Before fitting fascia panels, fit wiper blades,
reconnect battery and test wiper operation.
21.Refit fascia panels, noting that air conditioning
panel must be located and secured, on LH side,
with single screw, before instrument panel is
fitted.
22.Fit steering wheel
See STEERING, Repair,
Steering wheel.

ELECTRICAL
1
DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of electrical
connections at all times. Any incorrect connections
made when reconnecting cables may cause
irreparable damage to semi-conductor devices used in
generator and regulator. Incorrect polarity would also
seriously damage any transistorized equipment such
as a radio.
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect battery negative lead first. If
positive lead is disconnected with negative lead in
place, accidental contact of wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery positive lead should be
connected first.
GENERATOR
The generator is a three phase, field sensed unit. The
rotor and stator windings produce three phase
alternating current, AC, which is rectified to direct
current, DC. The electronic voltage regulator unit
controls generator output voltage by high frequency
switching of the rotor field circuit. Use only correct
replacement drive belt. Occasionally check that
engine and generator pulleys are accurately aligned.
It is essential that good electrical connections are
maintained at all times. Of particular importance are
those in the charging circuit (including those at
battery) which should be occasionally inspected to
see that they are clean and tight. In this way any
significant increase in circuit resistance can be
prevented.Do not disconnect battery cables while engine is
running or damage to semi-conductor devices may
occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while engine is running.
The electronic voltage regulator employs micro-circuit
techniques resulting in improved performance under
difficult service conditions. The whole assembly is
encapsulated in silicone rubber and housed in an
aluminium heat sink, ensuring complete protection
against adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give required regulating voltage range of 14.2±0.2
volts, and no adjustment is necessary. The only
maintenance needed is occasional check on terminal
connections and wiping with a clean dry cloth.
The generator system provides for direct connection
of a charge (ignition) indicator warning lamp, and
eliminates the need for a field switching relay or
warning light control unit. In the event of bulb failure,
an 'exciter' voltage is supplied through a resistor,
wired in parallel to the bulbs, ensuring that generator
output is maintained. The lamp should be checked
regularly.
When using rapid charge equipment to re-charge
battery, the battery must be disconnected from the
vehicle.