motor LAND ROVER DEFENDER 1996 User Guide

76CHASSIS AND BODY
28
REPAIR TAIL DOOR TRIM CASING
Service repair no - 76.34.09
Remove
1.Unscrew 2 bolts and remove grab handle from
rear door.
2.Remove 2 screws and detach wiper motor cover.
3.Remove 7 screws securing trim casing to door.
4.Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5.Carefully release 8 clips securing trim casing to
door.
6.Remove trim casing and collect door lock cover.
Refit
7.Position door lock cover, fit trim casing and
secure with clips.
8.Fit harness cover and secure with two screws.
9.Secure door panel with retaining screws.
10.Position wiper motor cover and secure with 2
screws.
11.Position grab handle and secure with 2 bolts.TAIL DOOR LOCK
Service repair no - 76.37.16
Remove
1.Remove door casing
See Tail door trim
casing
.
2.Remove screws, washers and nut retainer plate
securing top of lock to door.
3.Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4.Withdraw lock assembly.
5.Remove door lock gasket.
6.Clean sealant from retainer plates.
7.Insert key into barrel.
8.Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9.Fit new barrel into lock.
10.Apply sealant to lock retainer plates.
11.Fit lock to door with a new gasket.
12.Secure with retainer plates, screws, washers
and nuts.
13.Close door and check for correct latching with
striker. Adjust striker as necessary
See Tail
door striker - adjust
.
14.Fit door casing
See Tail door trim casing.

76CHASSIS AND BODY
34
REPAIRREV: 05/99 LOWER FASCIA PANEL (HEATER DUCT)
ASSEMBLY
Service repair no - 76.46.05
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel
.
3.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle
.
4.Remove instrument panel
See INSTRUMENTS,
Repair, instrument panel
.
5.Release heater cable at control lever
See
HEATING AND VENTILATION, Repair, Heater
control cable - air distribution
.
6.Remove 2 screws, withdraw switch panel from
lower fascia and disconnect switch multi-plugs.
7.Prise out Land Rover decal and remove screw
securing grab handle to crash pad.
8.Remove lower screw and lift grab handle from
lower fascia panel.
9.On RH drive vehicles only, remove screw
securing LH side of finisher to wiper motor cover.
10.Remove 4 screws and remove both demister
vents from crash pad.
11.Remove 3 screws securing crash pad to fascia
bulkhead.
12.Remove crash pad.
13.Remove radio, if fitted.
14.Remove 2 trim studs securing radio housing to
trim panel. Remove radio housing.

CHASSIS AND BODY
35
REPAIR REV: 05/99
15.If fitted, remove 2 screws, washers and nuts
securing auxiliary switch panel to lower fascia
panel and switch cover.
16.Withdraw switch panel and disconnect switch
leads.
17.Remove 2 screws securing switch cover to
parcel tray.
18.Remove fuse box cover.
19. Models with hand throttle:
Remove fuse box LH retaining screw.
Pivot fuse box down to gain access to lower
inner hand throttle cover fixing screw.
Remove 4 screws and lift up hand throttle cover
from lower fascia panel.
20.Remove 2 screws and remove both footwell
vents from lower fascia panel.
21.Remove single screw and detach door check
strap cover from LH and RH doors.
22.Remove 3 screws securing wiper motor cover to
fascia bulkhead.
23.Release locating pins from fascia panel, lower
wiper motor cover and, if applicable, disconnect
radio speaker leads. Retain wiper motor rack
cover. On LH drive vehicles, disconnect
multi-plugs from rear of switch panel.
24.Prise out 2 large and 5 small cap fasteners
securing trim panel to parcel shelf and fascia
bulkhead.
25.Carefully fold back trim panel to clear fresh air
vent operating levers and remove panel from
parcel shelf.

76CHASSIS AND BODY
36
REPAIRREV: 05/99 26.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
27.Remove parcel shelf.
28.Remove 7 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates.
29.Remove both retaining plates and lower footwell
covers.
30.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
31.With assistance, lower fascia panel and, if
applicable, disconnect RH radio speaker leads.
32.Remove fascia panel from vehicle.Refit
33.Position lower fascia panel to bulkhead,
reconnect RH speaker leads, if applicable, and
secure top edge with 2 bolts.
34.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
35.Repeat operation for LH footwell cover retaining
plate.
36.Fit remaining lower fascia panel fixing screws.
37.Locate parcel shelf. Ensure all radio and
auxiliary switch panel harness leads and plugs
are fed through aperture in parcel shelf.
38.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
39.Fit trim panel and secure with cap fasteners.
40.Reconnect LH speaker leads, if applicable,
locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated. On LH drive
vehicles, reconnect multi-plugs to rear of switch
panel.
41.Secure finisher to wiper motor cover.
42.Fit door check strap covers on both sides.
43.Fit footwell vents to lower fascia panel.
44. Models fitted with hand throttle:
Fit hand throttle cover.
Secure LH side of fuse box.
45.Fit fuse box cover.
46.Fit auxiliary switch cover to parcel tray, if
applicable.

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
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.

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.