service LAND ROVER DEFENDER 1996 Workshop Manual

82AIR CONDITIONING
2
REPAIR COMPRESSOR DRIVE BELT
Service repair no - 82.10.02
Remove
1.Disconnect battery.
2.Remove auxiliary drive belt
See ELECTRICAL,
Repair, Auxiliary drive belt.
3.Remove 3 nuts securing drive belt guard to
compressor retaining studs.
4.Slacken 3 belt tensioner retaining bolts.
5.Remove compressor drive belt. Mark direction
on belt if refitting.Refit
6.Fit compressor drive belt.
7.Fit drive belt guard.
8.Fit torque meter to centre of tensioner, apply and
hold a torque of
35 Nm (26 lbf/ft).
9.Tighten tensioner retaining bolts.
10.Rotate crankshaft 2 full turns.
11.Reapply and hold a torque of
35 Nm (26 lbf/ft)
to tensioner, then fully slacken and retighten
tensioner retaining bolts to
25 Nm (18 lbf/ft).
12.Fit auxiliary drive beltSee ELECTRICAL,
Repair, Auxiliary drive belt.
13.Reconnect battery.

AIR CONDITIONING
3
REPAIR CONDENSER FAN AND MOTORS
Service repair no - 82.15.08
Remove
1.Disconnect battery.
2.Remove 6 screws and lift grille panel from
vehicle.
3.Disconnect fan motor multi-plugs and release
harness retaining clips.
4.Remove nut and washers and withdraw fan
blade from motor drive shaft.
5.Remove 2 retaining screws, release motor fan
from shroud support brackets and feed motor
multi-plug lead through appropriate aperture.
Refit
6.Feed motor lead through fan shroud.
7.Fit motor to fan shroud support brackets.
8.Reconnect fan lead multi-plug and secure with
retaining clips.
9.Fit fan blade to motor drive shaft.
10.Fit grille panel.
11.Reconnect battery.CONDENSER
Service repair no - 82.15.07
Remove
1.Disconnect battery.
2.Recover refrigerant from air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
3.Remove 6 screws and lift grille panel from
vehicle .
4.Disconnect condenser fan motor lead
multi-plugs.
5.Disconnect receiver/drier dual pressure switch
multi-plug.
6.Disconnect condenser low pressure pipe at
compressor.
7.Disconnect high pressure hose/pipe at
evaporator.

AIR CONDITIONING
5
REPAIR RECEIVER/DRIER
Service repair no - 82.17.01
Remove
1.Disconnect battery.
2.Recover refrigerant from air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
3.Remove 6 screws and lift grille panel from
vehicle.
4.Disconnect receiver/drier dual pressure switch
multi-plug.
5.Disconnect high pressure pipe at receiver/drier.
6.Disconnect bottom union at condenser.
7.Remove retaining bolts and open clamps.
8.Release receiver/drier from condenser and
discard. It is NOT recommended to refit old unit.
9.Discard all pipe connection 'O' rings. Cap or plug
all connections to prevent ingress of dirt and
moisture.
Refit
10.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
11.Secure new receiver/drier in retaining clamp.
12.Fit receiver/drier bottom union connector at
condenser.
13.Fit high pressure pipe to receiver/drier.
14.Fit pressure switch multi-plug.
15.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
16.Reconnect battery.
17.Fit grille panel assembly.HEATER/COOLER UNIT - LH DRIVE
Service repair no - 82.25.21
Remove
1.Disconnect battery.
2.Recover refrigerant from air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
3.Remove expansion tankSee COOLING
SYSTEM, Repair, Expansion tank
to gain
access to air conditioning high and low pressure
pipes.
4.Disconnect high and low pressure pipes. Discard
pipe connection 'O' rings. Cap or plug
connections to prevent ingress of dirt and
moisture.
5.Disconnect compressor clutch switch multi-plug.
6.Remove pipe connector from vacuum switch.
7.Remove retaining clip and disconnect control
cable from evaporator flap operating rod.
8.Remove screw and release outer cable retaining
bracket.

AIR CONDITIONING
7
REPAIR EVAPORATOR - LH DRIVE
Service repair no - 82.25.20
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3.Release 3 nuts and remove mounting bracket
from underneath unit casing.
4.Remove 7 screws securing outlet duct to
heater/cooler unit.
5.Carefully break sealing compound around edge
of duct and pull ducting from unit.
6.Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
7.Remove 4 screws and 4 nuts from top of cover.
8.From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
9.At side of unit remove 2 screws adjacent to air
intake aperture.
10.Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
temperature probe which is inserted in
evaporator matrix through top cover.
11.Lift support plate and insulation pad from heater
matrix.
12.From bottom of unit casing, remove 3 screws
adjacent to dump valve outlet, and screws next
to heater matrix pipes.

82AIR CONDITIONING
8
REPAIR
13.Remove all other fixings securing evaporator
and heater matrix support frame to unit casing.
14.Lift evaporator and heater matrices, complete
with support frame assembly, clear of casing.
Retain heater matrix pipe seal pad.
15.Remove 4 screws securing evaporator matrix to
support frame.
16.Withdraw evaporator matrix, complete with
expansion valve, from support frame.
17.Clean sealing compound from all joints of main
casing, top cover and outlet duct.
NOTE: The evaporator matrix is supplied
complete with the expansion valve.
However, a faulty expansion valve can be
serviced separately,
See Expansion valve.
Refit
18.Fit evaporator matrix in support frame.
19.Fit evaporator, heater matrix and support frame
assembly in casing. Ensure studs for lower
mounting bracket are located through bottom of
casing.
20.Apply mastic sealant around heater matrix pipes
to seal pipe apertures in casing. Fit seal pad
over pipes.
21.Fit 3 bottom fixings to secure to secure base of
support frame.
22.Fit all other fixings to secure support frame
assembly.
23.Locate heater matrix insulation pad and cover
plate.
24.Apply sealng compound around top edge of
main casing.
25.Feed blower motor wiring through top cover and
fit grommet.
26.Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
27.Apply sealing compound to joint face of blower
motor outlet duct.
28.Locate duct over blower motor outlet and secure
to casing.
29.Secure lower mounting bracket to retaining studs
on base of main casing.
30.Fit heater/cooler unit assembly in engine
compartment
See Heater/cooler unit.

AIR CONDITIONING
9
REPAIR EXPANSION VALVE - LH DRIVE
Service repair no - 82.25.01
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3.Remove 7 screws securing outlet duct to
heater/cooler unit.
4.Break sealing compound around edge of duct
and pull duct from unit.
5.Remove all fixing screws securing top cover
seam and cover sides to main casing.
6.Remove 4 screws and 4 nuts from top of cover.
7.Break sealing compound from unit casing and
top cover.
8.Lift off top cover, release grommet and feed
blower motor wiring and air flap operating rod
through respective apertures. Note thermostat
temperature probe which is inserted in top of
evaporator.
9.Release 2 clips securing expansion valve sensor
and lagging to low pressure pipe.
10.Unscrew union securing expansion valve to
evaporator high pressure pipe.
11.Remove expansion valve, complete with high
pressure pipe.
12.Disconnect high pressure pipe from expansion
valve.
13.Discard all pipe connection 'O' rings.
14.Clean sealing compound from all joints of main
casing, top cover and outlet duct.
Refit
15.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
16.Fit high pressure pipe to new expansion valve.
17.Fit expansion valve to evaporator pipe
connector.
18.Position valve sensor at low pressure pipe and
secure with lagging and clips.
19.Apply sealing compound around top edge of
main casing.
20.Feed blower motor wiring through top cover and
fit grommet.
21.Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
22.Apply sealing compound to joint face of blower
motor outlet duct.
23.Locate duct over blower motor outlet and secure
to casing.
24.Fit heater/cooler unit
See Heater/cooler unit.

82AIR CONDITIONING
10
REPAIR HEATER MATRIX - LH DRIVE
Service repair no - 82.25.19
Remove
1.Remove evaporator
See Evaporator.
2.Leaving evaporator in place, remove single
screw securing heater matrix pipe plate to base
of support frame.
3.Remove heater matrix and insulation pad.
Refit
4.Position insulation pad and fit heater matrix to
support frame.
5.Fit heater matrix and evaporator assembly
See
Evaporator.
BLOWER MOTOR ASSEMBLY- LH DRIVE
Service repair no - 82.25.14
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit.
2.Remove 7 screws securing outlet duct to
heater/cooler unit.
3.Carefully break sealing compound around edge
of duct and pull ducting from unit.
4.Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
5.Remove 4 screws and 4 nuts from top of cover.
6.From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
7.At side of unit remove 2 screws adjacent to air
intake aperture.
8.Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
probe which is inserted in evaporator matrix
through top cover.

82AIR CONDITIONING
12
REPAIR BLOWER MOTOR ASSEMBLY - RH DRIVE
Service repair no - 82.25.14
Remove
1.Disconnect blower motor wiring plugs.
2.Remove 2 screws securing blower motor cover
to main casing.
3.Withdraw cover sufficiently to release motor
Lucar connector and earth eylet. Remove cover.
4.Remove 6 screws and withdraw blower motor
and impeller.
5.Remove retaining nut and washer and withdraw
impeller from blower motor shaft.Refit
6.Secure impeller on new blower motor.
7.Fit blower motor assembly in main casing.
8.Fit Lucar connector and earth eyelet to blower
motor.
9.Fit blower motor cover and connect wiring plugs.

AIR CONDITIONING
13
REPAIR HEATER/COOLER UNIT - RH DRIVE
Service repair no - 82.25.21
Remove
1.Disconnect battery.
2.Recover refrigerant from air conditioning system
See Refrigerant recovery, recycling,
recharging.
3.Release ties, remove insulation cover and
disconnect evaporator low pressure pipe.
4.Disconnect evaporator high pressure pipe.
5.Discard all pipe connection 'O' rings. Cap or plug
all connections to prevent ingress of dirt and
moisture.
6.Using suitable pipe clamps, clamp heater matrix
feed and return pipes at heater/cooler unit.
7.Remove screw securing air control flap solenoid.
8.Disconnect 2 leads from thermostat.
9.Remove pipe from water valve vacuum switch.
10.Remove retaining clip and disconnect control
cable from evaporator flap operating rod.
11.Remove screw and release outer cable retaining
bracket.12.Disconnect blower motor wiring plugs and
release harness retaining clip from housing.
13.Remove bolt securing front support bracket to
blower motor housing. If necessary, remove
blower motor resistor block to facilitate
operation.
14.From inside vehicle remove front passenger
carpet, if fitted.
15.Remove fixing screws and fold back footwell
insulation.
16.Remove 4 bolts securing heater/cooler unit lower
mounting bracket to bulkhead. Ensure spacing
washers from two innermost bolts are retrieved
from engine bulkhead side.
17.From inside engine compartment remove 2 bolts
securing top heater/cooler unit mounting bracket
to engine bullkhead.
18.Lift heater/cooler unit clear of air duct seal and
remove from vehicle.

AIR CONDITIONING
15
REPAIR EVAPORATOR - RH DRIVE
Service repair no - 82.25.20
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit - RH drive.
2.Suitably support unit on a bench.
3.Remove sealant and release thermostat probe
from low pressure pipe.
4.Remove 2 screws securing blower motor cover
to main casing.
5.Withdraw cover sufficiently to release motor
Lucar connector and earth eyelet. Remove
cover.
6.Unscrew top adaptor pipe from heater matrix.
7.Remove 18 fixings securing top cover to main
casing and heater/cooler support frame.
8.Carefully break sealing compound around edge
of joint seam and remove top cover from main
casing.
9.Lift out heater matrix.
10.Remove 2 screws securing back of evaporator
to support frame.
11.From underneath, remove 2 nuts and washers
securing evaporator matrix to base of casing.
12.Lift evaporator matrix from casing, complete with
side plates.
13.Remove side plates
14.Clean sealing compound from all joint seams of
main casing and top cover.
NOTE: The evaporator matrix is supplied
complete with the expansion valve.
However, a faulty expansion valve can be
serviced separately,
See Expansion valve - RH
drive.
Refit
15.Locate side panels to new evaporator lower
fixing studs.
16.Fit evaporator, with side plates, into main casing.
Ensure both studs are located through bottom of
casing and secure.
17.Apply sealing compound around joint seam of
main casing.
18.Fit top cover to main casing.
19.Fit thermostat probe to to low pressure pipe and
apply sealant.
20.Fit top adaptor pipe to heater matrix.
21.Fit Lucar connector and eath eyelet to blower
motor.
22.Fit blower motor cover.
23.Fit heater/cooler unit assembly into engine
compartment
See Heater/cooler unit.