1996 LAND ROVER DEFENDER air filter

FUEL SYSTEM
5
REPAIR FUEL FILTER ASSEMBLY
Service repair no - 19.25.02
Remove
1.Disconnect battery.
2.Place a suitable container under filter element
and slacken filter bleed screw.
3.Slacken drain tap and allow fuel to drain from
filter element.
4.Slacken fuel inlet and outlet banjo connections.
5.Remove 2 bolts and nuts securing filter head to
inner wing.
6.Remove fuel inlet and outlet banjo bolts and
detach fuel pipes.
7.Remove filter assembly from vehicle. Unscrew
filter element, if necessary.
8.Plug fuel pipe ends to prevent ingress of dirt.Refit
9.Position filter assembly and fit fuel inlet and
outlet pipes using new copper sealing washers
both sides of the banjo connections.
10.Secure filter head to inner wing.
11.Fully tighten banjo connections.
12.Prime fuel system to remove any air trapped in
filter
See Adjustment, Priming the fuel
system
13.Reconnect battery.
FUEL FILTER ELEMENT
Service repair no - 19.25.07
For remove and refit procedure.
See Fuel filter
element

COOLING SYSTEM
1
DESCRIPTION AND OPERATION ENGINE COOLING SYSTEM
Description
The complete cooling system of the 300Tdi engine
incorporates three independent functions:- Engine
(coolant) cooling; Turbo (charge air) intercooling;
Engine oil cooling.The intercooler is a separate aluminium unit, located
on the LH side of the engine compartment adjacent to
the radiator, sharing the same upper and lower
mountings. For details of turbo intercooling
See
FUEL SYSTEM, Description and operation,
Operation
. The oil cooler matrix is an integral part of
the radiator. Pre-formed pipes/hoses are used to link
the components within the separate systems as
shown below.
Engine cooling system
1.Radiator
2.Thermostat housing
3.Radiator bottom hose
4.Viscous fan
5.Water pump
6.Radiator top hose
7.Heater return hose
8.Coolant supply hose
9.By-pass hose
10.Radiator bleed (purge) hose
11.Bleed (purge) hose, thermostat housing
12.'Y' piece ejector
13.Expansion tank14.Heater rail
15.Heater unit
16.Heater feed hose
17.Intercooler
18.Air cleaner
19.Air feed hose
20.Turbocharger
21.Charge air supply pipe/hose
22.Cooled charge air supply hose
23.Exhaust manifold
24.Engine oil cooler
25.Feed pipe, engine oil cooler
26.Return pipe, engine oil cooler
27.Oil filter

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).

AIR CONDITIONING
3
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturers' instructions.
Recovery and recycling
1.Connect a Refrigerant Station to the high and
low pressure servicing connections.
2.Operate the refrigerant recovery system
according to the manufacturers instructions.
3.Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system. Recycling
should always be carried out with equipment
which is design certified by Underwriter
Laboratory Inc. for compliance with SAE-J1991.
Other equipment may not recycle refrigerant to
the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.
Evacuation and recharging
1.Add refrigerant oil to compressor if necessary.
2.Renew the receiver/drier.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
4.Operate the refrigerant evacuation system
according to the manufactures instructions.
NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes and then check the high
pressure lines.
CAUTION: The system must be Evacuated
immediately before recharging
commences. Delay between Evacuation
and Recharging is not permitted.