service LAND ROVER DEFENDER 1996 Workshop Manual

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
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
2
REPAIR BLOWER MOTOR
Service repair no - 80.20.15
Remove
1.Remove heater unit
See Heater unit.
2.Remove 3 nuts securing angled bracket to
heater unit. Pivot bracket to remove from studs.
3.Remove 5 nuts securing blower motor assembly
to volute housing.
4.Disconnect harness connector and remove
blower motor from volute housing.
5.Release circlip and withdraw impeller from motor
shaft.
6.Remove 3 nuts securing blower motor to
mounting plate.
7.Remove blower motor.
8.Examine components for signs of wear and
renew as necessary.
Refit
9.Apply Bostik 1261 adhesive to mating faces of
mounting plate and blower motor.
10.Fit blower motor to mounting plate and secure
with 3 nuts. Ensure rubber mountings are
correctly fitted.
11.Fit impeller to motor shaft and secure with circlip.
12.Position blower motor assembly in volute
housing and secure with 5 nuts. Fit angled
bracket to lower fixing.
13.Reconnect harness plug to resistor harness and
fit angled bracket to heater unit.
14.Fit heater unit
See Heater unit.HEATER MATRIX
Service repair no - 80.20.29
Remove
1.Remove heater unit
See Heater unit.
2.Remove 2 nuts securing angled bracket to
heater unit. Pivot bracket to remove from studs.
3.Remove 14 screws and detach two matrix
retaining plates from heater unit base.
4.Remove 9 screws securing matrix top retaining
plate.
5.Withdraw heater matrix through top of heater
unit casing.

HEATING AND VENTILATION
3
REPAIR Refit
6.Fit foam rubber to heater matrix casing.
7.Position matrix in heater unit casing.
8.Check that both vent flaps operate correctly
without sticking.
9.Secure matrix top retaining plate.
10.Secure matrix bottom retaining plates.
11.Fit heater unit
See Heater unit.RESISTOR UNIT
Service repair no - 80.20.17
Remove
1.Remove heater unit
See Heater unit.
2.Drill out 4 rivets securing resistor mounting plate
to top of volute housing.
3.Remove resistor and disconnect blower motor
plug from harness.
Refit
4.Apply Bostik adhesive to resistor mounting plate
and rivet to volute housing.
5.Reconnect blower harness motor plug.
6.Fit heater unit
See Heater unit.

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.

80HEATING AND VENTILATION
6
REPAIR HEATER CONTROL CABLE - AIR DISTRIBUTION
Service repair no - 80.10.12
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel.
3.Remove steering column nacelleSee
STEERING, Repair, Steering column nacelle.
4.Remove instrument panelSee INSTRUMENTS,
Repair, Instrument panel.
5.Remove retaining screws and pull off air
distribution and temperature control lever knobs.
6.Remove 3 screws and detach side cover,
complete with control lever assembly.
7.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.
8.Remove small bolt and release outer cable
retaining clip.
9.Slacken grub screw and release inner cable from
clevis.
10.Remove lower fascia panel assembly
See
CHASSIS AND BODY, Repair, Lower fascia
panel (heater duct) assembly.
11.Remove 19 screws and lift off heater duct cover.
12.Slacken vent flap trunnion fixing, release air
distribution control cable and remove from
heater duct.
13.Check condition of foam sealant on heater duct
cover and renew if necessary.

HEATING AND VENTILATION
7
REPAIR Refit
14.Fit new control cable through heater duct cover
and secure to vent flap trunnion. Bend over
cable end to fully secure.
15.Fit heater duct cover.
16.Fit lower fascia panel assembly to fascia
bulkhead
See CHASSIS AND BODY, Repair,
lower fascia panel (heater duct) assembly.
17.Route control cable along fascia bulkhead to
contol lever assembly.
18.With control lever in closed position, secure
cable to clevis.
19.Fit outer cable retaining clip to lever assembly.
20.Fit lever assembly to side cover. Ensure screw
spacers are fitted between cover and lever
assembly.
21.Fit side cover to fascia cowl.
22.Fit control lever knobs.
23.Fit instrument panel
See INSTRUMENTS,
Repair, Instrument panel.
24.Fit steering column nacelleSee STEERING,
Repair, Steering column nacelle.
CONTROL CABLE AND BLOWER MOTOR SWITCH
Service repair no - 80.10.17 - Control cable
Service repair no - 80.10.22 - Blower motor switch
Remove
1.Disconnect battery.
2.From inside engine compartment, release outer
cable retaining clip at heater unit.
3.Slacken trunnion fixing and release inner cable
from heater unit flap lever.
4.Release 2 retaining clips securing control cables
to engine bulkhead and heater hoses.
5.Remove 4 screws securing instrument panel to
fascia cowl.
6.Pull instrument panel away from fascia and
disconnect speedometer cable to ease access to
control cable.
7.Remove 2 screws securing control lever
assembly to side of fascia panel cowl. Note
plastic screw spacers fitted between cowl and
lever assembly and retain.

82AIR CONDITIONING
4
ADJUSTMENT 5.Operate the refrigerant recharging system
according to the manufactures instructions.
Refrigerant to charge system is 1.1 kg.
6.If the full charge has not been accepted by the
system, start the engine and run it at 1500
rev/min for a minimum of 2 minutes.
Switch on the air conditioning system, open the
vehicle windows, set the temperature control to
cold and switch the blower to maximum speed.
7.Consult Refrigerant Station Manual for correct
procedure to complete the charge.
8.Carry out the air conditioning system
performance test.LEAK TEST SYSTEM
The following instructions refer to an electronic type
Refrigerant Leak Detector for use with R134a, which
is the safest and most sensitive.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using an inert gas (see below).
1.Place the vehicle in a well ventilated area but
free from draughts, as leakage from the system
could be dissipated without detection.
2.Follow the instructions issued by the
manufacturer of the particular leak detector
being used.
3.Commence searching for leaks by passing the
detector probe around all joints and components,
refrigerant gas is heavier than air.
4.Insert the probe into an air outlet of the
evaporator or into the evaporator drain tube.
Switch the air conditioning blower on and off at
intervals of ten seconds. Any leaking refrigerant
will be gathered in by the blower and detected.
5.Insert the probe between the magnetic clutch
and compressor to check the shaft seal for
leaks.
6.Check all service valve connections, valve plate,
head and base plate joints and back seal plate.
7.Check the condenser for leaks at the pipe
unions.
8.If any leaks are found, the system must be
discharged before rectification.
9.Rectify any leaks and recheck for leaks during
evacuation prior to charging.
Leak test using inert gas
Use Nitrogen or Helium gas.
1.Connect gas line to recharging station.
2.Pressurise system to 3 bar.
3.Carry out leak test as above.

82AIR CONDITIONING
6
ADJUSTMENT SYSTEM TEST
1.Place the vehicle in a ventilated, shaded area
free from excessive draught, with the doors and
windows open.
2.Check that the surface of the condenser is not
restricted with dirt, leaves, flies, etc. Do not
neglect to check the surface between the
condenser and the radiator. Clean as necessary.
3.Switch on the ignition and the air conditioner air
flow control. Check that the blower is operating
efficiently at low, medium and high speeds.
Switch off the blower and the ignition.
4.Check that the evaporator condensate drain
tubes are open and clear.
5.Check the tension of the compressor driving belt,
and adjust if necessary.
6.Inspect all connections for the presence of
refrigerant oil. If oil is evident, check for leaks,
and repair as necessary.
NOTE: The compressor oil is soluble in
Refrigerant R134a and is deposited when
the refrigerant evaporates from a leak.
7.Start the engine.
8.Set the temperature controls to cold and switch
the air conditioner blower control on and off
several times, checking that the magnetic clutch
on the compressor engages and releases each
time.
9.With the temperature control at maximum
cooling and the blower control at high speed,
warm up the engine and fast idle at 1000
rev/min.
10.Repeat at 1800 rev/min.
11.Gradually increase the engine speed to the high
range and check the sight glass at intervals.
12.Check for frosting on the service valves.
13.Check the high pressure hoses and connections
by hand for varying temperature. Low
temperature indicates a restriction or blockage at
that point.
14.Switch off the air conditioning blower and stop
the engine.
15.If the air conditioning equipment is still not
satisfactory, carry out a pressure test as
previously described in this section.PRECAUTIONS IN HANDLING REFRIGERANT
LINES
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
1.When disconnecting any hose or pipe
connection the system must be discharged of all
pressure. Proceed cautiously, regardless of
gauge readings. Open connections slowly,
keeping hands and face well clear, so that no
injury occurs if there is liquid in the line. If
pressure is noticed, allow it to bleed off slowly.
2.Lines, flexible end connections and components
must be capped immediately they are opened to
prevent the entrance of moisture and dirt.
3.Any dirt or grease on fittings must be wiped off
with a clean alcohol dampened cloth. Do not use
chlorinated solvents such as trichloroethylene. If
dirt, grease or moisture cannot be removed from
inside the hoses, they must be replaced with
new hoses.
4.All replacement components and flexible end
connections must be sealed, and only opened
immediately prior to making the connection.
5.Ensure the components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters.
6.Components must not remain uncapped for
longer than 15 minutes. In the event of delay, the
caps must be fitted.
7.Receiver/driers must never be left uncapped as
they contain Silica Gel crystals which will absorb
moisture from the atmosphere. A receiver/ drier
left uncapped must not be used, fit a new unit.
8.The compressor shaft must not be rotated until
the system is entirely assembled and contains a
charge of refrigerant.
9.A new compressor contains an initial charge of
refrigerant oil. The compressor also contains a
holding charge of gas when received which
should be retained by leaving the seals in place
until the pipes are re-connected.
10.The receiver/drier should be the last component
connected to the system to ensure optimum
dehydration and maximum moisture protection of
the system.

AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Disconnect battery.
2.Recover refrigerant from air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
3.Remove compressor drive belt.See
Compressor drive belt
4.Disconnect high pressure pipe from compressor.
5.Disconnect low pressure pipe from compressor.
6.Remove 'O' ring from each flange.
7.Disconnect compressor clutch harness
multi-plug.
8.Remove compressor from mounting bracket
studs.Refit
9.If a new compressor is to be fitted first drain oil
from new compressor. Drain and measure oil
from old compressor. Measure new oil equal to
amount from old compressor, add 30 ml extra to
this amount and refill new compressor through
outlet port.
10.Locate compressor over mounting bracket studs.
11.Reconnect compressor clutch harness
multi-plug.
12.Fit new 'O' rings to high and low pressure hose
flanges, lubricate with refrigerant oil.
13.Fit high and low pressure hoses.
14.Fit compressor drive belt
See Compressor
drive belt.
15.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
16.Reconnect battery.
17.Perform a leak test on disturbed joints.
18.Carry out a functional check.