1996 LAND ROVER DEFENDER charging

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.

ELECTRICAL
1
DESCRIPTION AND OPERATION ELECTRICAL EQUIPMENT
Description
The electrical system is Negative ground, and it is
most important to ensure correct polarity of electrical
connections at all times. Any incorrect connections
made when reconnecting cables may cause
irreparable damage to semi-conductor devices used in
generator and regulator. Incorrect polarity would also
seriously damage any transistorized equipment such
as a radio.
WARNING: During battery removal or
before carrying out any repairs or
maintenance to electrical components
always disconnect battery negative lead first. If
positive lead is disconnected with negative lead in
place, accidental contact of wrench to any
grounded metal part could cause a severe spark,
possibly resulting in personal injury. Upon
installation of battery positive lead should be
connected first.
GENERATOR
The generator is a three phase, field sensed unit. The
rotor and stator windings produce three phase
alternating current, AC, which is rectified to direct
current, DC. The electronic voltage regulator unit
controls generator output voltage by high frequency
switching of the rotor field circuit. Use only correct
replacement drive belt. Occasionally check that
engine and generator pulleys are accurately aligned.
It is essential that good electrical connections are
maintained at all times. Of particular importance are
those in the charging circuit (including those at
battery) which should be occasionally inspected to
see that they are clean and tight. In this way any
significant increase in circuit resistance can be
prevented.Do not disconnect battery cables while engine is
running or damage to semi-conductor devices may
occur. It is also inadvisable to break or make any
connections in the generator charging and control
circuits while engine is running.
The electronic voltage regulator employs micro-circuit
techniques resulting in improved performance under
difficult service conditions. The whole assembly is
encapsulated in silicone rubber and housed in an
aluminium heat sink, ensuring complete protection
against adverse effects of temperature, dust, and
moisture etc.
The regulating voltage is set during manufacture to
give required regulating voltage range of 14.2±0.2
volts, and no adjustment is necessary. The only
maintenance needed is occasional check on terminal
connections and wiping with a clean dry cloth.
The generator system provides for direct connection
of a charge (ignition) indicator warning lamp, and
eliminates the need for a field switching relay or
warning light control unit. In the event of bulb failure,
an 'exciter' voltage is supplied through a resistor,
wired in parallel to the bulbs, ensuring that generator
output is maintained. The lamp should be checked
regularly.
When using rapid charge equipment to re-charge
battery, the battery must be disconnected from the
vehicle.

ELECTRICAL
1
FAULT DIAGNOSIS GENERAL INFORMATION
Detailed information of electrical systems, component
locations and circuit diagrams are covered in the
Defender Electrical Troubleshooting Manual.
This section covers checks of the charging system.
GENERATOR TESTING
Service repair no - 86.10.01
Charging system check
1.Check battery is in good condition, with an open
circuit voltage of at least 12.6 V. Recharge or
substitute battery to carry out test.
2.Check drive belt condition
See SECTION 10,
Maintenance, Under bonnet maintenance.
3.Check battery connections are clean and tight.
4.Check generator connections are clean and
tight.
5.Ensure there is no drain on battery from, for
example, interior or exteriorlamps.
Generator test
Following instructions refer to use of suitable test
equipment using a carbon pile rheostat.
6.Connect test equipment referring to
manufacturer's instructions.
7.Start engine and run at 3000 rev/min without
accessory load.
8.Rotate carbon pile load control to achieve
greatest output (amps) without allowing voltage
to fall below 12.0 V. A reading in amps, of
generator output should be obtained.
9.Run engine at 3000 rev/min, switch selector to
regulator test, read voltmeter. A reading of 13.6
to 14.4 V should be obtained.
10.Switch selector to diode/stator test, switch on
headlamps to load generator. Raise engine
speed to 3000 rev/min, read voltmeter, needle
must be within 'OK' range.TESTING IN POSITION
Charging circuit resistance test.
1.Connect a low range voltmeter between
generator terminal marked B+ and positive
terminal of battery.
2.Switch on headlamps, start engine. Run engine
at approximately 3000 rev/min. Note voltmeter
reading.
3.Transfer voltmeter connections to frame of
generator and negative terminal of battery, and
again note voltmeter reading.
4.If reading exceeds 0.5 volt on positive side or
0.25 volt on negative side, there is a high
resistance in charging circuit which must be
traced and remedied.

ELECTRICAL
1
REPAIR ELECTRICAL PRECAUTIONS
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to
electrical and electronic components fitted to the
vehicle.
Polarity
Never reverse connect the vehicle battery and always
observe the correct polarity when connecting test
equipment.
High voltage circuits
WARNING: Before commencing work on
an ignition system, all high tension
terminals, adaptors and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimize the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Whenever disconnecting live high tension circuits
always use insulated pliers and never allow the open
end of a high tension lead to come into contact with
other components particularly electronic control units.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, since, high
voltage spikes can occur on these terminals.
Connectors and harness
Always ensure that these items are dry and oil free
before disconnecting and connecting test equipment.
Never force connectors apart either by using tools or
by pulling on the wiring harness. Always ensure
locking tabs are disengaged before removal and note
orientation to enable correct reconnection. Ensure that
any protective covers and substances are replaced if
disturbed. Having confirmed a component to be faulty
switch-off the ignition and disconnect the battery.
Remove the component and support the disconnected
harness. When replacing the component keep oily
hands away from electrical connection areas and
push connectors home until any locking tabs fully
engage.Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately 15 minutes
afterwards, batteries emit hydrogen gas which is
flammable. Always ensure any battery charging area
is well ventilated and that every precaution is taken to
avoid naked flames and sparks.
GENERAL PRECAUTIONS
Switch-off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting 'live' connections can
damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only.
Prior to commencing a test, and periodically during a
test, touch a good earth, for instance, a cigar lighter
socket, to discharge body static as some electronic
components are vulnerable to static electricity.