wiring LAND ROVER DEFENDER 1996 Workshop Manual

04GENERAL SPECIFICATION DATA
8
INFORMATION Fuses
Type Autofuse (blade type) blow ratings to suit individual.................................................................................
circuits
Horns
Make/type Mixo TR99........................................................................
Starter motor
Make and type Bosch 12v.................................................................
BULBS
REPLACEMENT BULBS TYPE
Headlamps 12V 60/55W Halogen
Front side lamps 12V 5W bayonet
Side repeater lamps 12V 5W capless
Tail lamps 12V 5/21W bayonet
Direction indicator lamps 12V 21W bayonet
Number plate lamp 12V 5W capless
Reverse lamp 12V 21W bayonet
Rear fog guard lamp 12V 21W bayonet
Interior roof lamps 12V 10W festoon
Instrument illumination 12V 1.2W capless
Warning light panel 12V 1.2W bulb/holder unit
Hazard warning switch 12V 1.2W capless
CAUTION: The fitting of new bulbs with wattages in excess of those specified will result in damage
to vehicle wiring and switches.

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.

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.

AIR CONDITIONING
11
REPAIR
9.Remove screw securing blower motor mounting
bracket to side of casing.
10.Remove nut and washer securing blower motor
housing to pedestal mounting bracket.
11.Lift blower motor assembly from casing.
12.Remove 3 screws and withdraw blower motor
and impellor from housing. Note position of side
mounting bracket and spacing washers between
motor mounting and housing.
13.Remove star washer and withdraw impeller from
blower motor.
14.Lift motor from plastic mounting.
15.Slacken retaining clip and remove 3 support
brackets.Refit
16.Secure support brackets to new blower motor.
Do not fully tighten clip at this stage.
17.Insert motor into plastic mounting and fit
impeller.
18.Locate spacing washers, side mounting bracket,
and fit motor and mounting into motor housing.
19.Secure assembly to motor housing and fully
tighten support bracket retaining clip.
20.Fit blower motor assembly in main casing.
21.Apply sealing compound around top edge of
main casing.
22.Feed blower motor wiring through top cover and
fit grommet.
23.Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
24.Apply sealing compound to joint face of blower
motor outlet duct.
25.Locate duct over blower motor outlet and secure
to casing.
26.Fit heater/cooler unit
See Heater/cooler unit.

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.

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.