battery LAND ROVER DEFENDER 1996 Manual PDF

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.

82AIR CONDITIONING
4
REPAIR
8.Remove 4 bolts and large packing washers
securing fan cowling brackets to wing sides.
9.Remove 4 nuts securing fan cowling to lower
mounting bracket and lift complete assembly
from condenser.
10.Remove 2 bolts securing bonnet striker support
plate and cross braces to grille top panel.
11.Remove 2 bolts securing cross braces to front
wings.
12.Lift condenser, from bottom mounting lugs and
carefully ease forwards to clear top grille panel.
13.Lift condenser, complete with receiver/drier, from
vehicle taking care to clear high and low
pressure hose/pipes at side of radiator.
14.Disconnect condenser and receiver/drier pipes.
15.Remove clamp bolts and release receiver/drier if
a new condenser is to be fitted.
16.Discard all pipe connection 'O' rings. Cap or plug
all connections to prevent ingress of dirt and
moisture.Refit
17.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
18.Secure receiver/drier to mounting clamps.
19.Fit condenser and receiver/drier pipes.
20.Lower condenser into position ensuring high and
low pressure pipes are located between radiator
and front wing.
21.Secure cross braces and bonnet striker support
plate to top grille.
22.Secure cross braces to front wings.
23.Secure fan cowl assembly to lower mounting
bracket and front wings.
24.Fit high pressure pipe at evaporator.
25.Fit condenser low pressure pipe at compressor.
26.Connect multi-plug at receiver/drier dual
pressure switch.
27.Connect fan motor lead multi-plug.
28.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
29.Reconnect battery.
30.Fit grille panel.

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.

82AIR CONDITIONING
6
REPAIR 9.Remove plug connector from resistor.
10.Remove relay from connecting block to gain
access to fixing screw.
11.Remove screw and release relay connector
block. Retain relay in connector block.
12.Remove screw and detach air conditioning 30
amp fuse bracket from resistor. Refit both
resistor retaining screws.
13.Using suitable pipe clamps, clamp heater matrix
feed and return hoses at base of heater/cooler
unit. Release retaining clips and remove hoses.
14.From inside vehicle remove front passenger
carpet, if fitted.
15.Remove retaining screws and fold back footwell
insulation.
16.Remove 2 bolts securing heater/cooler unit lower
mounting bracket to bulkhead.
17.From inside engine compartment remove 2 bolts
securing top heater/cooler unit mounting bracket
to engine bulkhead. This also releases earthing
leads.
18.Remove bolt securing support bracket to front of
heater/cooler casing.19.Lift heater/cooler unit clear of air duct seal and
remove from vehicle.
20.Discard all pipe connection 'O' rings.
Refit
21.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
22.Position heater/cooler unit in engine
compartment and locate with air duct seal.
23.Secure unit top and bottom mounting brackets to
bulkhead and support bracket to front of unit
casing. Fully tighten fixing bolts when unit is
correctly positioned.
24.Fit footwell insulation.
25.Reconnect heater matrix hoses.
26.Fit air conditioning fuse bracket, relay connector
block, relay and resistor plug connector.
27.Fit control cable to evaporator air flap operating
rod, using a new clip.
28.Fit pipe connector to vacuum switch.
29.Connect compressor clutch switch multi-plug.
30.Connect high and low pressure pipes to
evaporator.
31.Fit expansion tank
See COOLING SYSTEM,
Repair, Expansion tank.
32.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
33.Reconnect battery.

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.

82AIR CONDITIONING
14
REPAIR Refit
19.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
20.Position heater/cooler unit in engine
compartment and locate with air duct seal.
21.Secure unit top and bottom mounting brackets to
bulkhead and support bracket to front of unit
casing. Fully tighten fixing bolts when unit is
correctly positioned.
22.If applicable, fit blower motor resistor block to
vehicle wing.
23.Connect blower motor wiring plugs.
24.Fit footwell insulation and carpet.
25.Fit control cable to evaporator flap operating rod
using new clip. Secure outer cable.
26.Connect water valve vacuum switch pipe and
thermostat leads.
27.Fit air control flap solenoid to side of
heater/cooler unit.
28.Reconnect heater matrix hoses.
29.Connect high pressure pipe to evaporator.
30.Connect low pressure pipe and fit insulation
cover.
31.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
32.Reconnect battery.

WIPERS AND WASHERS
1
REPAIR WIPER MOTOR AND DRIVE RACK
Service repair no - 84.15.09
Remove
1.Disconnect battery.
2.Remove wiper arms.
NOTE: Operations 3 - 5 are for RH drive
vehicles only.
3.Prise Land Rover decal from grab handle and
remove screw.
4.Remove lower screw and lift handle from fascia.
5.Remove screw fixing finisher to wiper motor
cover.
6.Remove door check strap cover, remove 3
screws and withdraw wiper motor cover. If
applicable, disconnect switch multi-plugs and/or
radio speaker leads.
7.Disconnect multi-plug from wiper motor.
8.Disconnect wiper motor earth lead. (Not
applicable on later models)
9.Lift rubber sleeve and slacken wiper motor to
drive tube nut.
10.Remove 2 screws and release wiper motor
retaining strap.
11.Fully unscrew tube nut.
12.Pull wiper motor and drive rack clear of tube and
retrieve mounting pad and earth tag.
Refit
13.Feed wiper motor drive rack into tube until fully
seated.
14.Loosely fit drive tube securing nut.
15.Fit wiper motor securing strap, earth tag and
mounting pad. Align motor and tighten fixing
screws.

84WIPERS AND WASHERS
2
REPAIR 16.Fully tighten tube nut and fit rubber sleeve.
17.Reconnect earth lead and multi-plug.
18.Before fitting cover and grab handle, fit wiper
blades. Reconnect battery and test operation of
wiper motor and drive assembly. If necessary,
adjust position of wiper blades.
19.Fit wiper motor cover and door check strap
cover.
20.On RH drive vehicles, fit finisher and grab
handle.

WIPERS AND WASHERS
3
REPAIR WIPER MOTOR AND DRIVE RACK - VEHICLE
WITH AIR CONDITIONING, LH DRIVE
Service repair no - 84.15.20
Remove
1.Disconnect battery.
2.Remove wiper arms.
3.Remove single screw and remove fascia side
panel.
4.Remove 5 screws and withdraw instrument
panel as far as possible without straining wires
and cables.
5.Remove steering wheel
See STEERING,
Repair, Steering wheel.
6.Remove 2 screws at RH side and single screw
at LH side, inside instrument cowel, and
withdraw air conditioning panel and controls.
7.Release fascia panel LH support bracket.
8.Remove wiper motor cover finisher.

84WIPERS AND WASHERS
4
REPAIR
9.Remove door check strap cover and 3 screws
and withdraw wiper motor cover. If applicable,
disconnect switch multi-plugs and/or radio
speaker leads.
10.Disconnect wiper motor multi-plug.
11.Disconnect earth lead. (Not applicable on later
models)
12.Lift rubber sleeve from wiper motor and slacken
wiper motor to drive tube nut.
13.Remove 2 screws and release wiper motor
retaining strap, complete with mounting pad and
earth tag.
14.Pull wiper motor and drive rack clear of drive
tubes.Refit
15.Feed drive rack into drive tube until fully located
in wheel boxes.
16.Finger tighten drive tube nut.
17.Position motor mounting pad, fit retaining strap,
including earth tag and secure wiper motor
assembly.
18.Fully tighten drive tube nut and fit rubber sleeve.
19.Fit wiper motor multi-plug and earth lead to tag
on motor retaining strap.
20.Before fitting fascia panels, fit wiper blades,
reconnect battery and test wiper operation.
21.Refit fascia panels, noting that air conditioning
panel must be located and secured, on LH side,
with single screw, before instrument panel is
fitted.
22.Fit steering wheel
See STEERING, Repair,
Steering wheel.