relay LAND ROVER DEFENDER 1999 Owner's Manual

41TRANSFER GEARBOX
8
REPAIR 17.Apply Hylomar PL32 sealant to switch threads.
18.Position switch into gearbox housing until
locknut/spacer bottoms out on housing.
19. Switches fitted with spacer:Tighten spacer
securing differential lock switch to11 Nm (8
lbf.ft).
20.Connect Lucars to switch.
21. Switches fitted with locknut:Adjust switch.
See Adjustment.
22.Fit and align tunnel cover, fit and tighten screws.
23.Fit hand-brake lever and tighten bolts to25 Nm
(18 lbf.ft).
24.Secure bulkhead carpet to LH side of tunnel.
25.Position relay/fuse panel, fit spacers and tighten
screws.
26.Fit insulation pad around gear levers.
27.Fit gear lever (s) gaiter.
28.Fit gearbox tunnel carpet.
29.Fit gear lever knobs.
30.Reconnect battery negative lead.
31.Fit battery cover.SEAL - INPUT SHAFT
Service repair no - 41.20.50
Remove
1.Remove transfer gearbox.See this Section.
2.Remove and discard input shaft oil seal from
transfer gearbox.
Refit
3.Clean oil seal recess in transfer gearbox.
4.Lubricate new oil seal with transfer gearbox oil.
5.UsingLRT-37-014, fit input shaft seal to transfer
gearbox.
6.Fit transfer gearbox.See this Section.
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TRANSFER GEARBOX
13
REPAIR SWITCH - LOW DETECT
Service repair no - 41.30.05
Remove
1.Remove battery cover.
2.Disconnect battery negative lead.
3.Remove gear lever knobs.
4.Remove gearbox tunnel carpet.
5.Remove gear lever(s) gaiter.
6.Release and remove insulation pad from around
gear levers.
7.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
8.Release bulkhead carpet from LH side of tunnel
and move aside.
9.Remove 2 bolts securing hand-brake lever to
body and move lever aside.
10.Remove 13 screws securing tunnel cover.
11.Release and remove tunnel cover.12.Release switch multiplug from bracket on
transfer gearbox, disconnect from harness.
13.Remove switch.
Refit
14.Clean switch and mating face on transfer
gearbox.
15.Fit nut/spacer to switch with counterbore
positioned towards switch head.
16.Apply Hylomar PL32 sealant to switch threads.
17.Fit switch and tighten to24 Nm (19 lbf.ft).
18.Connect multiplug to harness.
19.Fit and align tunnel cover, fit and tighten screws.
20.Position hand-brake lever and tighten bolts to25
Nm (18 lbf.ft).
21.Secure bulkhead carpet to LH side of tunnel.
22.Position relay/fuse panel, fit spacers and tighten
screws.
23.Fit insulation pad around gear levers.
24.Fit gear lever (s) gaiter.
25.Fit gearbox tunnel carpet.
26.Fit gear lever knobs.
27.Reconnect battery negative lead.
28.Fit battery cover.
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76CHASSIS AND BODY
2
DESCRIPTION AND OPERATION TAIL DOOR - FROM 02MY
1.Rubber window seal
2.CHMSL earth connection
3.CHMSL
4.Tail door glass and HRW element
5.Tail door CDL actuator
6.Rear wiper relay
7.Wiper motor
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CHASSIS AND BODY
3
DESCRIPTION AND OPERATION The tail door for 02MY is completely redesigned to address manufacturing complexity, corrosion and water ingress
probelms on previous tail doors.
The tail door is now a one piece outer skin pressing located on a reinforced steel, zinc plated frame. This gives
improved build quality, water integrity and minimal welding.
A new tail door glass is introduced with a one piece continuous rubber seal. The tail door glass has a revised
Heated Rear Window (HRW) element on the glass which removes the need to route wires up the sides of the
frame. The HRW element now has integral Lucar connections in the element which provide the earth connections
for the new centre high mounted stop lamp.
The inner trim panel is new and accommodates the CDL actuator and linkages.
The new tail door also contains a relay for rear wiper motor operation. Refer to the Wipers section for details.
Because the new tail door uses the current hinges and latch and retains the same geometry as the previous tail
door, the new tail door assembly is available as a service item for current vehicles.
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82 - AIR CONDITIONING
CONTENTS
Page
ADJUSTMENT
REFRIGERANT RECOVERY, RECYCLING, RECHARGING 1.............................
REPAIR
COMPRESSOR 1...................................................................................................
MOTOR - CONDENSER FAN 2..............................................................................
RECEIVER DRIER 2...............................................................................................
RELAY - TEMPERATURE CONTROL - FROM 02MY 3.........................................
EVAPORATOR 4....................................................................................................
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AIR CONDITIONING
3
REPAIR Refit
6.Position bracket to receiver drier and tighten
clamp bolt.
7.Position receiver to chassis and tighten bolts.
8.Remove plugs from A/C pipes.
9.Lubricate new’O’rings with refrigerent oil.
10.Fit’O’rings, position pipes and tighten bolts to8
Nm (6 lbf.ft).
11.Recharge A/C system.See Adjustment.RELAY - TEMPERATURE CONTROL - FROM 02MY
Service repair no - 82.20.40
Remove
1.Remove front speaker from drivers side.See
ELECTRICAL, Repair.
2.Release relay from support bracket.
3.Disconnect multiplug and remove relay.
Refit
4.Connect multiplug to relay and fit relay to
bracket.
5.Fit front speaker.See ELECTRICAL, Repair.
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82AIR CONDITIONING
4
REPAIR EVAPORATOR
Service repair no - 82.25.20
Remove
1.Remove battery cover.
2.Recover refrigerant from A/C system.See
Adjustment.
3.Remove 2 bolts securing A/C pipes to
evaporator.
4.Release pipes and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
5.Remove 2 screws and release fuse/relay bracket
from body and collect 2 spacers.
6.Remove 8 screws securing speakers to A/C
duct.
7.Disconnect speaker Lucars and remove
speakers.
8.Remove 4 screws and bolt securing A/C duct to
fascia panel.
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AIR CONDITIONING
5
REPAIR
9.Disconnect multiplug from auxiliary relay
bracket.
10.Release drain pipe from evaporator.
11.Release evaporator from bulkhead grommet.
12.With assistance remove A/C duct assembly from
vehicle.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
13.Disconnect blower motor multiplugs.
14.Remove 5 screws and remove blower unit from
A/C duct.
15.Disconnect multiplug from trinary switch.
16.Remove Allen screw, remove pipe assembly
from evaporator and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
17.Remove 7 screws and remove evaporator cover
from A/C duct.
18.Release temperature sensor and remove
evaporator.
19.Remove 2 Allen screws, remove TXV from
evaporator and discard’O’rings.
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82AIR CONDITIONING
6
REPAIR Refit
20.Clean TXV and mating face.
21.Lubricate new’O’rings with refrigerant oil and fit
’O’rings to pipes.
22.Position TXV and tighten Allen screws.
23.Position evaporator and fit sensor.
24.Position cover and tighten screws.
25.Clean pipes and mating faces.
26.Lubricate and fit new’O’rings, position pipes
and tighten Allen screw.
27.Connect trinary switch multiplug.
28.Position blower unit,tighten screws and connect
multiplugs.
29.With assistance position A/C duct assembly to
vehicle.
30.Connect drain pipe to evaporator.
31.Connect multiplug to relay bracket.
32.Align A/C duct to fascia, tighten securing bolt
and screws.
33.Position speakers and connect Lucars.
34.Position relay bracket and tighten bolts.
35.Clean pipes and mating face.
36.Lubricate and fit new’O’rings to evaporator
pipes.
37.Position pipes and tighten bolts to6Nm(4
lbf.ft).
38.Renew receiver drier.See this Section.
39.Recharge A/C system.See Adjustment.
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84 - WIPERS AND WASHERS
CONTENTS
Page
DESCRIPTION AND OPERATION
WINDSCREEN WIPERS - FROM 02MY 2..............................................................
REAR WIPER - FROM 02MY 4..............................................................................
REPAIR
PUMP - WINDSCREEN WASHER 1......................................................................
JET - REAR SCREEN WASHER 1.........................................................................
ARM - WIPER - FROM 02MY 2..............................................................................
WIPER MOTOR AND DRIVE RACK - FROM 02MY 3............................................
WHEELBOX/DRIVE PIVOT - FROM 02MY 4.........................................................
RELAY - WIPER DELAY - FROM 02MY 5..............................................................
MOTOR - WIPER - TAIL DOOR - FROM 02MY 6..................................................
RELAY - TAIL DOOR WIPER - FROM 02MY 7......................................................
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