window LAND ROVER DEFENDER 1996 User Guide

76CHASSIS AND BODY
22
REPAIR Refit
9.Fit new spring clips to the 3 brackets on top
edge of side trim panel.
10.Align trim panel, ensuring it is correctly
positioned around side window.
11.Locate trim panel spring clips on inner cant rail
and press firmly down to secure top edge of trim
panel.
12.Align bosses of trim panel with body side fixing
holes and secure with 4 bolts and washers. Do
not fully tighten at this stage.
13.Fit trim stud to secure bottom edge of trim panel
to 'B' post.
14.Secure seat belt guide to 'B' post, tighten bolt to
32 Nm (24 lbf/ft)and fit cap.
15.Fit rear end trim panel
See Rear end trim
panel
.
16.Fit rear seat squab
See Rear seat squab.SIDE TRIM PANEL - 110 STATION WAGON
Service repair no - 76.13.70
Remove
1.Remove rear inward facing seats
See Rear
seat squab - 90
,orSee Rear bench seat.
2.Remove rear end trim panel
See Rear end
trim panel
.
3.Prise finisher cap from rear seat belt upper guide
bracket retaining bolt.
4.Unscrew bolt and remove guide bracket from 'C'
post.
5.Remove bolt securing seat belt to wheel arch
mounting.
6.Prise trim panel cap fastener from 'C' post.
7.Remove seat belt aperture finisher from side trim
panel.
8.Remove screw and release seat belt clip from 'C'
post.

CHASSIS AND BODY
23
REPAIR
9.Remove fixings securing bottom edge of trim
panel to body side.
10.Release top edge of trim panel by striking
upwards with the hand to disengage 3 spring
clips.
11.Lift trim panel from window surround and feed
seat belt through panel aperture.
12.Remove trim panel from vehicle.
Refit
13.Fit new spring clips to the 3 brackets on top
edge of side trim panel.
14.Feed seat belt through aperture in trim panel and
fit finisher.
15.Align trim panel, ensuring it is correctly
positioned around side window.
16.Locate trim panel spring clips on inner cant rail
and press firmly down to secure top edge of trim
panel.
17.Align bosses of trim panel with body side fixing
holes and secure with bolts or screws. If
individual type seats are fitted do not fully tighten
fixings at this stage.
18.Fit seat belt clip to 'C' post.
19.Fit trim panel cap fastener to 'C' post.
20.Fit seat belt to wheel arch. Tighten bolt to
32 Nm
(24 lbf/ft).
21.Fit seat belt guide bracket to 'C' post. Tighten
bolt to
32 Nm (24 lbf/ft)and fit finisher cap.
22.Fit rear end trim panel
See Rear end trim
panel
.
23.Fit inward facing seats
See Rear seat squab,
or
See Rear bench seat.REAR END TRIM PANEL - 90/110 STATION
WAGON
Service repair no - 76.13.71
Remove
1.Pull edge of rear end trim panel firmly to release
2 spring retaining clips from vertical rail at door
aperture.
2.Remove rear end trim panel.
Refit
3.Fit new spring clips to the 2 brackets on side of
trim panel.
4.Position outboard edge of trim panel in corner to
abut side trim panel and locate spring clips on
vertical rail.
5.Press edge of trim panel firmly to secure in
position.

82AIR CONDITIONING
2
DESCRIPTION AND OPERATION Operation
Evaporator unit and expansion valve
High pressure liquid refrigerant is delivered to the
expansion valve which is the controlling device for the
air conditioning system. A severe pressure drop
occurs across the valve and as the refrigerant flows
through the evaporator it picks up heat from the
ambient air, boils and vaporizes. As this change of
state occurs, a large amount of latent heat is
absorbed. The evaporator is therefore cooled and as
a result heat is extracted from the air flowing across
the evaporator. The refrigerant leaves the evaporator,
on its way to the compressor, as a low pressure gas.
An evaporator sensor measures the air temperature at
the evaporator and engages or disengages the
compressor clutch to prevent icing of the air ways.
Compressor
The compressor, a pump specially designed to raise
the pressure of the refrigerant, is mounted on the front
of the engine and is driven by an independent drive
belt from the crankshaft pulley. The compressor draws
vaporized refrigerant from the evaporator. It is
compressed with a resulting rise in temperature and
passed on to the condenser as a hot, high pressure
vapour.
Condenser
The condenser is mounted directly in front of the
radiator and consists of a refrigerant coil mounted in a
series of thin cooling fins to provide the maximum
heat transfer. Air flow across the condenser is induced
by vehicle movement and assisted by two electric fans
attached to the frame of the condenser. The
refrigerant high pressure vapour enters the condenser
inlet on the RH side. As the vapour passes through
the condenser coils the air flow, assisted by the two
fans, carries the latent heat away from the condenser.
This induces a change of state resulting in the
refrigerant condensing into a high pressure warm
liquid. From the condenser, the refrigerant continues
to the receiver/ drier.
Receiver/drier
This component acts as a reservoir and is used to
hold extra refrigerant until it is needed by the
evaporator. The drier within the receiver unit contains
a filter and dessicant (drying material) which absorb
moisture and prevent dessicant dust from being
carried with the refrigerant into the system.AIR CONDITIONING AND HEATER CONTROLS -
LH DRIVE
1. Temperature control
Move the lever upwards (RED) to increase air
temperature, or downwards (BLUE) to reduce air
temperature.
2. Air conditioning switch
Press the switch (indicator lamp illuminates) to
activate the air conditioning. Press again to switch off.
3. Air recirculation control
Move the lever fully upwards to activate air
recirculation. Move the lever fully downwards to
cancel recirculation.
NOTE: Prolonged recirculation may cause
the windows to mist up.
4. Air distribution control
Lever fully up - air to windscreen vents (also provides
some air to the footwell).
Lever midway - air to fascia vents (also provides some
air to the footwell).
Lever fully down - air to footwell vents (also provides
some air to the windscreen).

82AIR CONDITIONING
4
DESCRIPTION AND OPERATION 5. Air distribution control
Push LH button - air to windscreen vents (also
provides some air to the footwell).
Push middle button - air to fascia vents (also provides
some air to the footwell).
Push RH button - air to footwell vents (also provides
some air to the windscreen).
6. Air recirculation switch
Press the LH portion of the switch to activate air
recirculation. Press the RH portion for fresh air.
NOTE: Prolonged recirculation may cause
the windows to mist up.

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.

AIR CONDITIONING
5
ADJUSTMENT AIR CONDITIONING SYSTEM - PERFORMANCE
TEST
WARNING: R134a is hazardousSee
Repair, General Precautions
Carry out this test with bonnet and doors or windows
open, air conditioning switched on, temperature
control set to cold and blower at maximum speed. Set
the air supply control to supply fresh air.
1.Close low pressure valve on refrigerant station.
2.Close high pressure valve on refrigerant station.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.4.Insert dry bulb thermometer into cold air outlet
and position dry and wet bulb thermometer close
to outside air inlet.
Do not spill water from the wet thermometer
(psychrometer).
5.Start engine and run it at 1500 rev/min for 10
minutes with air conditioning switched on.
6.Read both pressure gauges and thermometers.
Check readings against table below with
humidity between 60% and 80%.
7.Switch off air conditioning, stop engine,
disconnect test equipment.
Performance range
Intake temperature Outlet temperature Low pressure High pressure
20 - 24°C4-10°C 18 - 28 lbf/in
2213 - 299 lbf/in2
1.2 - 1.9 bar 14.7 - 20.6 bar
25 - 29°C9-19°C 27 - 37 lbf/in2256 - 341 lbf/in2
1.9 - 2.6 bar 17.6 - 23.5 bar
30 - 35°C20-27°C 33 - 47 lbf/in2299 - 384 lbf/in2
2.3 - 3.2 bar 20.6 - 26.5 bar
Table 1
Ambient Compound Gauge High Pressure
Temperature Readings Gauge Readings
°C°F bar lbf/in
2bar lbf/in2
16 60 1,03-1,4 15-20 6,9-10,3 100-150
26,7 80 1,4-1,72 20-25 9,6-13,1 140-190
38 100 1,72-2,1 25-30 12,4-15,5 180-225
43,5 110 2,1-2,4 30-35 14,8-17,2 215-250

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.

ELECTRICAL
5
DESCRIPTION AND OPERATION REV: 05/99 ALARM SYSTEM OPERATION
Arming alarm
To arm the alarm, aim handset at vehicle and press
the RH button (Padlock symbol). Provided all doors
and or apertures are closed, the direction indicator
lamps will flash three times to confirm that the alarm is
armed. All security features previously described will
be active.
Once armed, the alarm will sound if a door or the
bonnet is opened, or if movement is detected inside
the vehicle.
Disarming alarm
Within range of the vehicle, briefly press the LH
(Plain) button on the handset; the direction indicator
lamps will flash once to indicate that the alarm has
been disarmed and the engine re-mobilised.
NOTE: In some territories, the interior
lamps will illuminate when the alarm is
disarmed.
If the direction indicators fail to flash when the
alarm is armed:
This indicates that a door or the bonnet is not fully
closed, in which case the alarm will be partially armed
and engine immobilised, but interior protection will not
be active.
Once the open door or bonnet is closed, the direction
indicators will flash three times and the alarm will fully
arm as described previously.
If the alarm sounds:
The vehicle horn and alarm sounder will operate
continuously for 30 seconds when the alarm is
triggered. The horn and alarm sounder can be
triggered up to three times.
To silence the alarm, press either handset button. If
the handset is inoperative, the alarm can only be
disarmed by entering the emergency key access
code, seeEngine immobilisation override.Anti-theft alarm indicator light
A RED indicator light on the instrument panel
indicates the status of the alarm system. When the
alarm is armed successfully, the light flashes rapidly.
After 10 seconds, the light adjusts to a slower
frequency and continues flashing as an anti-theft
deterrent.
If the light fails to illuminate during the rapid flash
phase, this indicates a 'mislock' (door or the bonnet
not fully closed or key in starter switch). If this occurs,
the indicator light will still flash at slower frequency as
an anti-theft deterrent.
The indicator light will illuminate continuously under
the following conditions:
1.Alarm system armed and immobilised with
ignition 'on' or driver's door open.
2.Engine immobilised with ignition 'on' or driver's
door open.
Interior protection
Interior protection is activated automatically when the
alarm system is armed; twin sensors inside the
vehicle monitor interior space and will activate the
alarm if an intrusion is detected.
However, if passengers or animals are to be left inside
the vehicle, or if a window or sunroof is to be left
open, the alarm must be armed with the interior
protection DISABLED as follows:
To disable interior protection:
1.Open the driver's door.
2.Use the handset to arm the alarm in normal way.
3.Close the driver's door (the direction indicator
lamps will flash three times and the anti-theft
indicator light commences flashing rapidly). The
alarm system is now armed with the interior
protection disabled.
NOTE: Interior protection will not operate
until 15 seconds after the alarm is set.

ELECTRICAL
7
DESCRIPTION AND OPERATION ALARM SYSTEM FUSES
When the vehicle immobilisation and alarm system is
fitted, three fuses are used to protect the circuit:
·Alarm system 15 amp fuse, main harness, located
behind instrument binnacle.
·Alarm sounder 20 amp fuse No.10, located in main
fuse box.
·Alarm system 5 amp fuse No.20, located in main
fuse box.
The main fuse box is positioned in the centre of the
fascia, in front of the main gear lever. A label in the
fuse box cover shows the circuits protected, the fuse
rating and their locations. They are also listed below.
MAIN FUSE BOX
Fuse No. Value (amps) Electrical circuit
1 15 Hazard warning lights
2 20 Interior lamp, horn
3 15 Wipers & washers - rear
4 10 Wipers & washers - front
5 15 Heater
6 7.5 Rear fog guard lamps
7 5 Radio/cassette player
8 15 Heated rear window
9 10 Cigar lighter
10 20 Alarm sounder
11 7.5 Headlamp - RH, dipped beam
12 7.5 Headlamp - LH, dipped beam
13 7.5 Headlamp - RH, main beam
14 7.5 Headlamp - LH, main beam
15 5 Side lamps - LH
16 5 Side lamps - RH
17 15 Stop & reverse lamps
18 20 Air conditioning
19 5 Air conditioning
20 5 Alarm system