Defender (1993+). Manual — part 100

ELECTRICAL EQUIPMENT

NOTE:

Soak new bushes in engine oil for thirty

minutes before fitting.

Reassembly

Armature

27.

Check the armature insulation using suitable
test equipment. Connect the tester between
any one commutator segment and the shaft.
The method illustrated uses a 110 V, 15 W

34. Reverse the instructions 1 to 22. Smear the

test lamp. If the lamp illuminates the armature

teeth and operating collar of the roller clutch

is

faulty, and a replacement component

IS

with Shell Retinax 'A' grease. Smear the pivot

required.

lever of the drive assembly with Mobil 22
grease. Smear the drive shaft sun and planet
gears with

Rocol

ERE1200 grease.

35. Tighten all the fixings

to

the correct torque

-

see Torque Wrench Settings, SECTION 06

.

HEADLAMPS

To remove or renew bulb o r light unit

1. Remove the

two

screws and withdraw the

2. Remove the two screws and withdraw the

front flasher lens.

3. Remove the three screws retaining the side

lamp to the wing.

4.

Remove the three screws securing the flasher
lamp.

5.

Ease the side and flasher lamps from their

28. If necessary, the commutator may be

locations in the wing and pull them out as far
as the leads will allow.

6. Remove the screws retaining the plastic bezel

to

the wing.

7 .

Withdraw the bezel sufficiently to gain access
to the headlamp retaining screws.

front side lamp lens.

machined, providing a finished surface can be

obtained without reducing the diameter below
28.8

mm

otherwise a new commutator must

be fitted. Finish the surface with fine emery
cloth.

Do

not undercut the insulation

slots.

Drive assembly

29. Test the roller clutch. The pinion should rotate

in one direction only, independent of the
clutch body. Replace the unit

if

unsatisfactory

or if teeth are damaged or worn.

Bearings

30. Renew the bearing bushes

if

there is evidence

of armature fouling magnets or if there is
perceptible side play between the shaft and

bush.

31. Drive end/intermediate end bracket: press out

the bush using a suitable press and mandrel.

32.

Press the new bush in, ensuring that on the

drive end bracket, the bush

I

S

flush with the

casting.

33. Commutator end bracket: thread a 9/16

Whitworth or suitable similar tap firmly into the
bush. Extract the bush with the tap using a

power press in reverse.

12

REISSUED: FEB 1993

ELECTRICAL

EQUIPMENT

11

Discard the light unit, or release the spring

8.

Remove the three screws retaining the rim

clip and discard the bulb if faulty.

and light unit, and remove the rim.

12.

If required, fit a new bulb of the correct

9.

Withdraw the light unit or reflector and

wattage and secure with the spring clip, or

fit

disconnect the electrical connector.

a new light unit.

10

Remove the rubber grommet.

14. Disconnect the electrical leads from the bullet

connectors and remove the headlamp shell.

15. Remove the rubber seal.

To remove or renew headlamp assembly

13.

Remove the four screws and release the

16.

Release the two trimmer screws and coil
spring and detach the rim seating from the
headlamp shell.

headlamp shell from the front wing.

REISSUED: FEB

1993

13

ELECTRICAL EQUIPMENT

Assemble and refit

27. The

beam centres

'A'

are

measured

horizontally on the vehicle and the dimension
'B' vertically from the ground.

17.

Fit the rim seating to the headlamp shell with

the two trimmer screws and coil spring.

18. Fit the rubber seal to the headlamp shell.
19. Connect the leads to the bullet connectors.

20. Fit the headlamp shell into the front wing

locating the trimmer screws into the

two

holes

in

the wing. Ensure that the assembly is

located, as illustrated, with one trimmer screw

at the 12 o'clock position and the other 90° to
the left.

21. Secure the shell assembly to the wing with

the four screws.

22. Offer-up the light or reflector unit to the rim

seating and connect the electrical connector.

23. Secure the assembly with the rim and three

screws.

24. Refitting

of

the plastic bezel and lamps

is

a

reversal of instructions 1 to 7. Ensure,
however, that when fitting the side and flasher
lamps the gap in the seal surround is located
at the bottom to provide for drainage and
ventilation.

25. Remember to replace or renew the rubber

sealing washers over the screws inside each
lens. Also check that the fibre washers are in
place under the screw heads on the outside

of

the lens.

25.

Check the main beam setting using beam

setting equipment. Should this not be
available the beam can be temporarily
checked and adjusted in the following way:-

26.

Position the vehicle on level ground with the

tyres correctly inflated, approximately four
meters from a wall or screen, marked as
illustrated.

14

REISSUED:

FEB

1993

ELECTRICAL EQUIPMENT

SIDE, TAIL AND FLASHER LAMPS

Renew bulbs and lamps

REAR

NUMBER

PLATE LAMP

Remove and renew bulbs

1.

Disconnect the battery.

1.

Disconnect the battery and remove the single

2. Remove the two screws and fibre washers

and withdraw the lens and collect the two
rubber washers inside the lens.

3.

Disconnect the electrical leads.

screw securing the lamp cover and lens.

2.

At this stage the bulbs only can be renewed.

3. Push the bulb inwards, twist and withdraw.

4.

Remove the cover from inside the vehicle

4.

Remove the three screws and withdraw the

body.

lamp

holder

complete.

Disconnect the

5.

Remove the two nuts and washers securing

electrical leads from the bullet connectors

the lamp to the vehicle body.

inside the vehicle wing for the front lamps. For

6.

Remove the bulb holder complete with rubber

rear lamps remove the cover inside the body

seal and mounting block.

for access to the connectors.

5. If

necessary remove the rubber bulb holder

cover.

Refitting lamp and bulbs

6. Fit the rubber cover to the lamp holder.
7.

Ensure that the drain gap in the cover is at

the bottom.

8.

Connect the electrical leads to the bullet

7 .

Assemble the bulb holder and rubber seal to

connectors.

9.

Fit the lamp to the vehicle, observing

the mounting block, connect the leads and fit
to the vehicle body with the two screws and

instruction 7 , and secure with the three

nuts.

screws.

10.

Fit the bulb of the same wattage, if renewed.

8. Fit the bulbs.
9. Fit the lens and lamp cover and secure with

11.

Fit the lens ensuring that the rubber and fibre
washers are correctly positioned. Evenly

the single screw. Connect the battery and test

tighten the

two

screws. Overtightening could

the lamp.

crack the lens.

Refitting lamp and bulbs

REISSUED:

FEB

1993

15