Land Rover Defender Workshop 1993 Rover Manual

							ELECTRICAL EQUIPMENT 
REAR LAMPS REVERSE LIGHT SWITCH 
1. The rear  lamp  cluster  on  the  left  side Remove and refit 
comprises  a  rear/stop lamp  an amber flasher 
lamp  and  a  white reverse  lamp.  The 
reverse  light  switch  is  located at the  rear  of the 
On  the  right  side the  lamp  cluster  comprises  gear  change  housing  and  is accessible  from 
only  rear/stop  lamp  and  flasher.  underneath  the  vehicle. 
Loctite thread  locking  fluid 
rubber  using a flat  screwdriver  to gain  access 
to the  bulbs. Removal 
The  lenses  are marked Top to ensure 
correct  re
-assembly. 1. Disconnect the  battery  negative lead. 
3. The lamp  units are secured  by nuts, 2. Disconnect  the  electrical  leads  from  the 
accessable  under the rear  fender.  Three  nuts 
and  bolts  retain  the  left  lamp  cluster  and 
two 3. Unscrew  the switch  from the gear  change 
nuts  and bolts  secure 
the right lamp  cluster. 
2. The  lenses  are easily  levered  out of the  should  be  used when  fitting this switch. 
reverse  light, switch. 
housing. 
Refitting 
4. Coat  the switch  threads  with Loctite 290. 
5. Fit  the  reverse light switch to the gear  change 
housing  and tighten 
to 12 Nm. 
6. Connect  the electrical leads  to  the switch. 
7. Connect the battery  negative  lead. 
16 REISSUED: FEB 1993  
						

							ELECTRICAL EQUIPMENT 
WARNING LAMPS INSTRUMENT ILLUMINATION 
Renew the bulbs  Renew bulbs 
1. Disconnect  the  battery. 1 Disconnect  the battery. 
2. Remove two screws  and  withdraw  the warning 2. Remove  the  four screws  retaining  the 
light  module  from  the front of the  instrument  instrument  panel. 
panel. 
3. Ease  forward  the  panel to gain  access to the 
3. Pull off the plug  connector to give  access  to  bulbs. 
warning  light  bulbs, 
If necessary, disconnect  the  drive cable  from  the 
4. Twist the  bulb  holder  and  pull  it  from  its back of the  speedometer. 
socket.  4. Twist  the  bulb  holder  and pull it from  its 
5. Pull the  bulb  from the holder.  socket. 
6. Fit a new bulb  and refit  the  holder  and  plug 
connector. 
6. Fit  a new  bulb  and refit the holder. 
7.  Refit  the module. 
8 Connect  the battery. 7. Replace the  instrument  panel. 
5. 
Pull  the  bulb from  its  holder. 
8. Connect the  battery. 
REISSUED: FEB 1993 17  
						

							ELECTRICAL EQUIPMENT 
WIPER MOTOR - OVERHAUL 
INSPECTION AND 
TEST 
DISMANTLE 
14. 
Check  the  brushes  for excessive wear,  if they 
1. Remove  the wiper  motor  and drive  from  the  are worn  to 4,8  mm  in length, fit a new  brush 
vehicle.  gear assembly. 
2. Remove  the wiper  motor  gearbox  cover. 15. Using  a  push type  gauge,  check that  the 
3.  Remove 
the  circlip  and  plain washer  securing  brush  spring  pressure 
IS 140 to 200 g when 
the connecting  rod.  the  bottom 
of the  brush 
is level  with  the 
4. Withdraw  the connecting  rod.  bottom 
of the  slot  in the  brush  box.  Fit a new 
5.  Withdraw  the flat washer.  brush 
gear  assembly 
if the springs  are not 
6.  Remove  the circlip  and  washer  securing  the  satisfactory. 
shaft  and gear.  16. 
Test  the  armature  for insulation  and open  or 
7. Clean  any  burrs  from  the gear  shaft  and  short-circuits. Use a 110 V 15 W test  lamp.  Fit 
withdraw  the gear.  a  new armature 
if faulty. 
8. Withdraw 
the dished  washer.  17.  Examine  the  gear wheel  for damage  or 
9. Add alignment  marks to  the  yoke and gearbox  excessive wear. 
for  reassembly. 
10. Remove  the yoke  securing  bolts. 
11. Withdraw  the yoke  and armature. 
12. Remove  the brush  gear assembly. 
13.  Remove  the limit  switch. 
18 
REISSUED: FEB 1993  
						

							ELECTRICAL EQUIPMENT 
ASSEMBLE 
Use Ragosine  Listate  Grease  to  lubricate  the  gear 
wheel  teeth,  armature  shaft  worm gear, Connecting 
rod  and  pin, cable  rack  and wheelbox  gear  wheels. 
Use  Shell  Turbo 
41 oil sparingly  to lubricate  the 
bearing  bushes,  armature  shaft  bearing  journals, 
gear  wheel  shaft and  wheelbox  spindles.  Thoroughly 
soak  the felt washer 
in the  yoke  bearing  with  oil. 
20.  Fit  the  armature to  gearbox using KEY  TO  WIPER MOTOR  COMPONENTS alignment marks, secure with the yoke 
retaining  bolts  tightening  to  23  Kg 
f cm. If a 
replacement  armature  is  being  fitted slacken 
the thrust screw 
to provide  end-float  for fitting 
21.  Fit the dished  washer beneath  the  gear  wheel 
with  the concave  side  towards the gear  wheel. 
22.  Fit the  gear  wheel 
to the  gearbox. 
23.  Secure  the gear  wheel  shaft with the plain 
washer  and circlip. 
10. Yoke  securing bolts 
24. 
Fit the  larger  flat  washer  over the crankpin. 
25.  Fit  the  connecting  rod  and secure  with the 
11. 
Armature  and  yolk 
12. Brush  gear  assembly 
smaller 
plain washer  and  circlip. 
13. Limit switch 26. Fit the  gearbox  cover  and secure  with the 
retaining  screws. 
27.  Connect  the  electrical  leads between  the 
wiper  motor  and limit  switch. 
28. To adjust  the  armature  shaft  end-float,  hold 
the  yoke  vertically  with the adjuster  screw 
uppermost.  Carefully  screw
-in  the  adjuster 
until  resistance  is  felt,  then  back
-off  one 
quarter  turn.  1 . 
Flexible drive 
2.  Gearbox  cover 
3. Connecting-rod retaining  washer  and circlip 
4.  Connecting
-rod 
5. Fiat  washer 
6. Gear  shaft retaining  washer and circlip 
7. Drive  gear 
8. Dished  washer 
9. Alignment  marks - yoke to body 
REISSUED:  FEB 1993 19 
18.  Fit  the  limit  switch. 
19.  Fit  the  brush  gear  assembly. 
the  yoke.  
						

							ELECTRICAL EQUIPMENT 
RENEW WIPER MOTOR AND DRIVE RACK 
Removing  wiper motor 
1. Disconnect  the battery. 
2. Remove  the wiper  arms. 
3. Remove  the single  screw  and remove  the 
fascia  side panel. 
4. Remove  the five  screws  and withdraw  the 
instrument  panel as far  as possible  without 
straining  the wires  and cables. 
8. Release  the fascia  panel left-hand support 
bracket. 
9. Remove  fascia lower panel  finisher. 
10. Remove  fascia lower panel. 
5. Remove  the single  screw  securing  steering 
wheel  centre  pad. 
6. Turn steering  wheel to straight  ahead position 
and  mark  the relationship 
of the  steering 
wheel 
to the  column  and remove  the nut. 
Withdraw  the wheel  using special 
tool 18G 
1014 or a suitable  alternative  puller. 
7. To remove the air conditioning  panel and 
controls,  remove the 
two screws at the  right 
hand  side of the  panel  and the single  screw at 
the  left
-hand  side, inside  the instrument  cowl. 
20 REISSUED: FEB 1993  
						

							ELECTRICAL EQUIPMENT 
11. 
12. Remove earth lead. 
13.  Lift rubber  sleeve  from wiper  motor  and 
Remove 
slacken  wiper motor  to drive  tube nut. 
14.  Remove  the wiper  motor  retaining  strap 
1. Pull the wiper  arm away  from the windscreen. 
screws  and remove  strap together  with  2. Using  a small  screwdriver,  hold back  the 
mounting  pad and earth  tag.  spring clip which  retains  the arm  to the 
15.  Pull 
the wiper  motor  and drive  rack clear  of 
the  drive  tubes. 
Disconnect 
the wiper  motor  wiring  multiplug. 
RENEW  WINDSCREEN  WIPER ARMS 
spindle adaptor. 
3. Pull the wiper  arm from  the splined  adaptor. 
4.  Switch  the wiper  motor  to the 
park position 
with  the grub  screw,  retaining  the adaptor, 
uppermost. 
5.  Push  the arm 
on to the  adaptor so that  the 
wiper  blade  is just  clear 
of the windscreen 
surround  rubber. 
6.  Operate  the wipers  and 
if necessary  adjust 
the  position  of the  arms. 
Fitting wiper  motor 
16.  Feed  the drive  rack into the drive  tube until 
fully  located  in the  wheel  boxes. 
17. Finger  tighten  the drive  tube nut. 
18.  Position  the motor  mounting  pad and  secure 
the  assembly  with the strap 
and screws  not 
forgetting  the earth  tag. 
19. Tighten  the drive  tube nut and  position  the 
rubber  sleeve over the nut. 
20.  Connect  the multiplug  to the  motor  and the 
earth  lead to the  tag  on motor  retaining  strap. 
21.  Before  fitting the fascia  panels,  fit the  wiper 
blades,  connect  the battery  and test  the wiper 
operation. 
22.  Refit  the fascia  panels  noting that the air 
conditioning  panel must be located  and 
secured,  on the  left side,  with the single 
screw,  before the instrument  panel is fitted. 
23.  Fit the  steering  wheel ensuring  that the marks 
made  during  removal  coincide.  Fit and  tighten 
the  securing  nut to the  correct  torque. 
24.  Fit the  steering  wheel centre  pad with  the 
single  screw. 
REISSUED: FEB 1993 21  
						

							ELECTRICAL EQUIPMENT 
RENEW WINDSCREEN  WIPER WHEELBOXES 
Remove 
7.  Remove  demister  vent top duct. 
6. Remove  right-hand vent demister  vent fixing 
and  pivot  vent and hose  aside. 
8. Release  the steering  column upper and lower 
9. Slacken  the left and  right-hand  wheelbox  nuts 
1. Disconnect  the battery.  support rods. 
2.  Carry
-out the  instructions  to remove  the wiper 
motor  and drive  rack for air conditioned  and remove  drive tubes  from wheelboxes. 
vehicles,  that is:  10. Remove  wiper arm splined  adaptor. 
Wiper  arms  11. Remove  spacer, where fitted, early vehicles 
Fascia  side panel  only. 
Instrument  housing  12. Remove  nuts securing  left and  right
-hand 
Fascia  top crash  rail  wheel 
boxes  and withdraw  wheelboxes  from 
Steering  wheel  bulkhead. 
Fascia  panel air conditioning  controls 
Fitting wheelboxes 
NOTE:  It is  important  that during  the following 
assembly  the fixings  related  to the  wiper 
motor 
and  wheelboxes  are finger  tightened  only until all 
Wiper 
motor  and drive  rack 
3. Remove  centre and left-hand  fascia  top crash 
rail  support  bracket fixings. 
4. Remove  left and  right-hand  demister  vents the components  are correctly  aligned. 
from ducts. 
5.  Remove  right
-hand demister  vent hose  from 
duct. 
22 REISSUED:  FEB 1993  
						

							ELECTRICAL EQUIPMENT 
13. Fit the  wheelboxes to the bulkhead  and ELECTRICAL SYSTEMS 
loosely secure with the nut and  washer. 
14. Loosely  fit the  drive  tubes  to the  wheelboxes  The electrical  systems on the  vehicle  are made up of 
15. Feed  the drive  rack through  the tubes  until  separate  harnesses  of which  the Engine  Harness, 
fully  seated  in both  wheelboxes.  Chassis 
Harness  and Main  Harness  Assembly  are 
16. Loosely secure drive tube nut to wiper motor. the  main  components.  These three harnesses 
17 Loosely fit the wiper  motor  strap and earth  connect  together  and to smaller  individual 
lead.  component harnesses to form  the vehicle  harness. 
18. When all components  are correctly  aligned,  Each harness  can be separated  and replaced 
tighten  the wheelbox  nuts to secure  the drive 
individually  The harnesses  are shown  in situ  in the 
tubes.  Tighten  the wheelbox  to bulkhead  nuts.  vehicle. 
19. Finally tighten  the dnve  tube nut to wiper 
motor  and motor  strap screws.  The 
following  harness descriptions  include listings of 
20.  Connect  the multiplug 
to wiper  motor  and  the items  connected onto each harness  and the 
earth  lead 
to strap tag.  colour 
coding  of the  relevant  cables For information 
21.  Fit the  spacer,  where used, early vehicles  on the  individual  circuits which form the vehicle 
only.  electrical 
system, refer to the  Circuit  Diagrams. 
22.  Fit the  wiper  arm adaptors. 
23. Connect  the battery  and check  the operation For information on the  location  and identification  of 
of  the  motor  and drive  assembly  and relays. timers and control  units, refer to the  table  and 
wheelboxes.  illustration in this  section. 
24.  Disconnect  the battery  and reverse 
instructions  2 
to 10. Ensure that the steering 
column  upper and lower  support  rod fixings 
are  tightened 
to the correct  torque. 
25.  Reconnect  the battery  and check  wiper 
operation  again and adjust  arms 
if necessary. 
23 RE-ISSUED: FEB 1993  
						

							ELECTRICAL EQUIPMENT 
ENGINE HARNESS 
This harness  connects  various electrical  items fined 
to the engine  and associated  systems with the  This harness  connects  air conditioning  fans and 
vehicle  electrics  via the  main  cable  assembly. 
On associated  switches to the  electrical  system through 
Defender  110 
the air conditioning  fans harness is a Connection  onto the main  harness  assembly 
attached 
to the  engine  harness. 
The items  making  up the  harness  and the cable 
The  items  making 
up the harness  and cable  colours  colours are: 
are:  Left hand  fan motor 
Oil pressure  switch and sensor  Colours: 
black/red,  black 
Colours:  light green/white,  white/brown 
Right hand fan motor 
Coil  Colours: black/red,  black 
Colours:  black/white 
Alternator  leads  Colours: black/yellow,  yellow/black 
Colours:  brown/yellow,  brown, white/slate  (grey) 
Colours:  white/green,  white, white 
Air  conditioning  compressor lead, 
110 only 
Colours:  black, brown/pink 
Water  temperature  transmitter  Colour: white 
Colours:  green/blue 
Starter  solenoid 
Colours:  brown/red,  brown 
Air  conditioning  cable connections, 
110 only  Colours: black/red,  black/red,  black, brown/orange, 
Colours:  black, brown/pink,  white/green  white/green 
Dash  ground  connection  Compressor 
clutch relay module 
Colour:  black  Colours: black/slate,  brown/slate,  whitelpurple, 
brown/pink 
Main  harness  connection 
Colours:  brown/red,  green/blue,  white/slate, 
light In dash control  unit 
green/white,  white/brown.  brown/yellow, white 
Colours: white/purple 
Blower 
fan relay  module  connections 
Colours:  black, brown,  white 
Air  conditioning  harness connections 
Colours:  brown/pink.  black, white/green 
AIR CONDITIONING  FANS HARNESS  ASSEMBLY 
DEFENDER 
110 ONLY 
High  pressure  switch 
Ranco  thermostat 
Fan  temperature  switch, 
110 only  Colours: black/yellow,  white/purple, white/purple 
Toe box ground  connection 
Colours:  black 
x 3 
Single  lead to auxiliary  connection 
on main harness 
Main  harness  connections 
Colours:  brown, brown/slate,  brownlorange 
Condenser  fan relay  module 
24 REVISED: OCT 1993  
						

							ELECTRICAL EQUIPMENT 
CHASSIS  HARNESS Vehicle speed sensor 
Colours:  green/yellow 
This  harness  connects  the rear  lights  and fuel tank 
electrics  with the main  harness:  various individual  Centre differential  locked switch connection 
items  are also  connected  to the  chassis  harness  Colours: black/purple. slate/red 
Including  the hi-mount  stop lamp  cable 
Vehicle speed sensor  MFI connection 
The  items  making  up the  harness  and the cable 
Colour: yellow 
colours  are: 
Reverse light switch  connection 
Right  hand rear lights  connections 
to the following  Colour: green 
Ground  connection 
Colour:  black  Transmission 
oil temperature 
connection 
Colour:  black/purple 
Tail  light 
Colours:  red/orange  Main 
harness  assembly  connections 
Colours:  red/light green, green, brown/light  green, 
Indicator  lamp  black/blue, green/red, red/orange,  green/purple. 
Colours:  green/white  red/yellow, 
purple, red/black,  green/white 
Reverse  lamp 
Colours:  green/brown,  green/brown 
Stop  lamp 
Colours:  green/purple,  green/purple 
Trailer  feed (both  sides)  Defender  110 
Colours:  purple, purple 
Rear  lamp  connections 
Colours: black/brown,  black/white 
Heated  rear window 
Colours:  white/black,  black 
Rear  wash  wipe 
Colours:  green, white/light  green, black/light  green 
Rear  tank connections 
Colours:  black, whiter/purple,  green/black, black 
Left  hand  rear lights  connections  to the  following: 
Rear  lamp  connection 
Colours  black/green,  green/blue 
Ground  connection 
Colours: black 
Indicator  lamp 
Colours: green/red 
Reverse  lamp 
Colours: green/brown 
Stop  lamp 
Colours:  green/purple 
Tail  light 
Colours:  red/black 
REVISED:  OCT 1993 25