engine LAND ROVER DEFENDER 1996 Workshop Manual

70BRAKES
4
REPAIR PRESSURE REDUCING VALVE (PRV)
Service repair no - 70.25.21
Remove
1.Disconnect battery.
2.Clean area around reducing valve ports.
3.Place a container under valve to catch escaping
brake fluid.
4.Disconnect primary circuit pipe unions ñAñ
from valve.
5.Disconnect secondary circuit pipe unions ñBñ
from valve.
6.Cover pipes to prevent ingress of dirt.
7.Remove single retaining nut and bolt securing
valve to engine bulkhead.
8.Remove valve.
Refit
9.Fit valve to engine bulkhead. Tighten bolt to
15
Nm (11 lbf/ft).
10.Connect primary and secondary circuit pipes to
valve. Tighten to
16 Nm (12 lbf/ft).
11.Fill brake reservoir with recommended brake
fluid
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
.
12.Bleed the brake system
See Brake system
bleed
.
13.Reconnect battery and road test vehicle.SERVO NON RETURN VALVE
Service repair no - 70.50.15
Remove
1.Disconnect brake vacuum hose from servo non
return valve.
2.Carefully prise valve out with a screwdriver blade
between valve and grommet. Take care not to
exert too much pressure on the vacuum
chamber.
3.Remove rubber grommet but be careful not to
allow it to fall into the vacuum chamber.
4.Check the valve for correct operation; it should
not be possible to pass air through into the servo
in direction of arrow. Do not use compressed air.
Refit
5.Fit rubber grommet.
6.Smear ribs of the valve with Lucas Girling rubber
grease to assist assembly, and push valve fully
home.
7.Connect vacuum hose to the valve.
8.Road test vehicle.

BRAKES
5
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting repair refer to general brake service
practice
See General Brake Service Practice.
NOTE: The non-return valve and grommet,
are the only serviceable components. In
event of failure or damage, fit a new unit.
1.Remove master cylinderSee Master cylinder.
2.Disconnect vacuum supply hose from servo unit.
3.At footwell, release 2 brake pedal return springs.
4.Disconnect leads from brake light switch at rear
of pedal box.
5.Remove blanking grommets from each side of
pedal box.
6.Remove split pin and clevis pin securing servo
push rod to brake pedal.
7.Remove 4 nuts and plain washers securing
servo to pedal box.
8.Remove servo assembly and rubber washer
from bulkhead.Refit
9.Locate servo assembly and rubber washer to
engine bulkhead and secure to pedal box.
Tighten fixings to
14 Nm (10 lbf/ft).
10.Fit brake pedal to servo push rod with clevis pin
and new split pin.
11.Fit blanking grommets to each side of pedal box.
12.At footwell, attach pedal return springs.
13.Connect vacuum hose to servo non-return valve.
14.Fit brake master cylinder to servo unit
See
Master cylinder
.

70BRAKES
6
REPAIR BRAKE PEDAL
Service repair no - 70.35.01 - Brake pedal
Service repair no - 70.35.03 - Pedal box
Remove
1.Remove brake servo assembly.
See Servo
assembly
.
2.Remove 6 bolts securing pedal box to engine
bulkhead.
3.Taking care not damage brake fluid pipes,
remove pedal box assembly and gasket.
4.Release return springs from pedal and pedal box
bosses.
5.Using a suitable punch, drift out retaining pin and
withdraw pedal pivot shaft.
6.Remove brake pedal complete with pivot
bushes.
7.Examine components for wear or damage,
renew as necessary.
8.If it is necessary to fit new pivot bushes, they
must be reamed out to 15,87 mm±0,02 mm
(0.625±0.001 in) after fitment.Refit
9.Lubricate pedal pivot shaft and bushes with
general purpose grease.
10.Fit pedal to pedal box, insert pivot shaft and
secure with new split pin.
11.Attach return springs to pedal and pedal box
bosses.
12.Fit pedal box and gasket to engine bulkhead.
Tighten fixings to
25 Nm (18 lbf/ft).
13.Fit brake servo assembly.See Servo
assembly
.

70BRAKES
18
REPAIR VACUUM PUMP
Service repair no - 70.50.19
Remove
NOTE: To ease pump removal set engine
to T.D.C. on No.1 cylinder.
1.Disconnect battery.
2.Remove air cleaner
See FUEL SYSTEM,
Repair, Air cleaner
.
3.Detach servo hose from vacuum pump.
4.Remove bolt securing air cleaner support
bracket strut.
5.Remove 6 bolts securing vacuum pump.
6.Detach pump complete with strut and harness
bracket. Note location of strut and bracket for
Refit.
Refit
7.Clean mating faces of pump and block.
8.Loosely assemble pump to block with a new
gasket and with air cleaner strut and harness
bracket located under heads of bolts noted
during Remove.
9.Evenly tighten bolts, to depress pump plunger,
finally tightening to
25 Nm (18 lbf/ft).
10.Secure strut to air cleaner bracket.
11.Connect vacuum hose and secure with clip.
12.Refit air cleaner
See FUEL SYSTEM, Repair,
Air cleaner
.

CHASSIS AND BODY
39
REPAIR ACCESS PANEL - FRONT UNDERTRAY
Service repair no - 76.11.85 - Access panel
Service repair no - 76.11.83 - Acoustic pad
The access panel is provided in the front undertray to
enable fitment of the wading plug into the engine
timing cover.
Remove
1.Raise vehicle on ramp.
2.Remove 5 bolts securing access panel to front
undertray.
3.Remove access panel.
4.If necessary, remove 5 fasteners and release
acoustic pad from access panel.
Refit
5.If applicable, fit acoustic pad to access panel.
6.Fit access panel to front undertray, Tighten
fixings to
14 Nm (10 lbf/ft).
7.Lower ramp.ACCESS PANEL - REAR UNDERTRAY
Service repair no - 76.11.84
The access panel is provided in the rear undertray to
enable fitment of the wading plug or timing tool
LRT-12-044in the flywheel housing, and access to
the engine oil sump drain plug.
Remove
1.Raise vehicle on ramp.
2.Rotate access panel anti-clockwise to release
locking flanges.
3.Remove access panel from undertray.
Refit
4.Locate access panel flanges in undertray
apertures.
5.Rotate panel clockwise to secure in undertray.
6.Lower ramp.

HEATING AND VENTILATION
1
DESCRIPTION AND OPERATION HEATING AND VENTILATION SYSTEM
Description
The heating and ventilation system is standard on all
models. Air conditioning is an optional system which
provides fully integrated climate control for the vehicle
interior.The heater assembly, comprising a matrix housed in a
distribution unit and a variable speed blower motor, is
located on one side of the engine compartment and
attached directly to the fascia bulkhead.
The heating controls are positioned on the outside of
the instrument binnacle and cable linked to
mechanical flaps in the distribution unit.
Heater assembly
1.Heater distribution unit
2.Fixings, heater to fascia bulkhead
3.Heater matrix
4.Blower motor housing
5.Circlip, impeller to blower motor
6.Impeller
7.Resistor unit and harness connector8.Fixings, blower motor mounting plate
9.Mounting plate, blower motor
10.Blower motor
11.Fixings, blower motor to mounting bracket
12.Temperature flap, air flow to heater matrix
13.Air flap, air supply to plenum chamber (heater
duct)

80HEATING AND VENTILATION
2
DESCRIPTION AND OPERATION HEATER OPERATION
The heater matrix (3), located in the distribution unit
(1), see J6341, is connected to the engine cooling
system. As water is circulated continuously through
the matrix, a selection of heated or ambient air is
controlled by two flaps within the distribution unit. The
temperature flap (12) controls the amount of ambient
air to the heater matrix, air being suppliedthrough a ducted vent on top of the vehicle front wing
to the blower motor (volute) housing (4). The blower
motor (10) can be used to boost the air flow into the
distribution unit. The air flap (13) controls the supply of
heated or ambient air from the heater unit into a
plenum chamber integeral with the vehicle fascia. Two
flaps in the plenum chamber (heater duct) distribute
the air flow to either the footwell vents or windscreen
demister vents as shown.
HEATER CONTROLS
1. Temperature control
Move the lever downwards to increase air
temperature or up to decrease air temperature.
2. Air distribution control
Lever fully up - windscreen vents only.
Lever midway - footwell and windscreen vents.
Lever fully down - footwell vents.3. Blower motor fan speed control
Move the lever progressively downwards to increase
fan speed. With the control at '0' the fan is switched
off and the volume of air entering the passenger
compartment is solely dependent on ram air when the
vehicle is moving.

HEATING AND VENTILATION
1
REPAIR HEATER UNIT
Service repair no - 80.20.01
Remove
1.Remove bonnet and disconnect battery.
2.Remove radiator bottom hose at radiator union
and drain cooling system
See COOLING
SYSTEM, Repair, Drain and refill cooling
system
.
3.Slacken clips and remove heater hoses at
heater box unions.
4.Remove outer cable securing clips.
5.Slacken trunnions and remove control cables
from heater vent flap levers.
6.Remove heater wiring harness securing loop.
7.Disconnect harness multi-plug.
8.Remove interior bulkhead trim.
9.Remove lower nuts and bolts securing the
heater unit to the bulkhead.
10.Slacken heater unit upper retaining bolts.
11.Manoeuvre heater unit, complete with blower
motor, clear of air inlet duct and remove from
engine compartment.
12.If existing heater unit is to be refitted, remove
sealing rubber.
For heater matrix removal
See Heater matrix.
For blower motor removal
See Blower motor.
Refit
13.Smear a new heater unit sealing rubber with a
suitable impact adhesive and fit to heater.
14.Manoevre heater unit into position in engine
compartment, fit blower motor to air inlet duct
and locate upper fixing bolts.
15.Loosely fit heater unit lower fixing bolts.
16.Fully tighten upper fixing bolts.
17.Fully tighten lower fixings and refit interior
bulkhead trim.
18.Secure wiring harness and reconnect multi-plug.
19.Fit control cables to vent flap trunnions and
secure with outer cable clips.
20.Connect heater hoses.
21.Fit radiator bottom hose and refill cooling system
See COOLING SYSTEM, Repair, Drain and
refill cooling system
.
22.Fit bonnet and reconnect battery.

80HEATING AND VENTILATION
4
REPAIR HEATER CONTROL CABLE - TEMPERATURE
CONTROL
Service repair no - 80.10.05
Remove
1.Disconnect battery.
2.Remove 4 screws securing instrument panel to
fascia cowl.
3.Pull instrument panel away from fascia and
disconnect speedometer cable to give easier
access to control cable at bulkhead.
4.Remove retaining screws and pull off air
distribution and temperature control lever knobs.
5.Remove 3 screws and detach side cover,
complete with control lever assembly.
6.Remove 2 screws securing control lever
assembly to side cover and remove cover. Note
plastic screw spacers fitted between cover and
control lever assembly and retain.
7.Remove small bolt and release outer cable
retaining clip.
8.Slacken grub screw and release inner cable from
clevis.
9.From inside engine compartment, release outer
cable retaining clip at heater unit.
10.Slacken trunnion fixing and release inner cable
from heater unit flap lever.
11.Release 2 retaining clips securing control cables
to engine bulkhead and heater hoses.
12.Pull control cable through bulkhead grommet
and remove from vehicle.
Refit
13.Fit new control cable to heater flap lever trunnion
with approximately 10 mm of inner cable
protruding from trunnion. Fully tighten trunnion.
14.Secure outer cable with retaining clip.
15.Route control cable through sealing grommet
and along inside of engine bulkhead to fascia
panel.

HEATING AND VENTILATION
5
REPAIR 16.Secure control cables to engine bulkhead and
heater hoses with retaining clips.
17.With control lever in closed position, fit inner
cable to lever clevis and fully tighten clevis grub
screw.
18.Fit outer cable retaining clip and fully tighten
securing bolt.
19.Fit side cover to control lever assembly. Ensure
fixing screw spacers are positioned between
cover and lever assembly.
20.Fit side cover to fascia.
21.Fit control lever knobs.
22.Reconnect speedometer cable and fit instrument
panel.
23.Reconnect battery.