1996 LAND ROVER DEFENDER heating

HEATING AND VENTILATION
5
REPAIR 16.Secure control cables to engine bulkhead and
heater hoses with retaining clips.
17.With control lever in closed position, fit inner
cable to lever clevis and fully tighten clevis grub
screw.
18.Fit outer cable retaining clip and fully tighten
securing bolt.
19.Fit side cover to control lever assembly. Ensure
fixing screw spacers are positioned between
cover and lever assembly.
20.Fit side cover to fascia.
21.Fit control lever knobs.
22.Reconnect speedometer cable and fit instrument
panel.
23.Reconnect battery.

80HEATING AND VENTILATION
6
REPAIR HEATER CONTROL CABLE - AIR DISTRIBUTION
Service repair no - 80.10.12
Remove
1.Disconnect battery.
2.Remove steering wheel
See STEERING,
Repair, Steering wheel.
3.Remove steering column nacelleSee
STEERING, Repair, Steering column nacelle.
4.Remove instrument panelSee INSTRUMENTS,
Repair, Instrument panel.
5.Remove retaining screws and pull off air
distribution and temperature control lever knobs.
6.Remove 3 screws and detach side cover,
complete with control lever assembly.
7.Remove 2 screws securing control lever
assembly to side cover and remove cover. Note
plastic screw spacers fitted between cover and
control lever assembly and retain.
8.Remove small bolt and release outer cable
retaining clip.
9.Slacken grub screw and release inner cable from
clevis.
10.Remove lower fascia panel assembly
See
CHASSIS AND BODY, Repair, Lower fascia
panel (heater duct) assembly.
11.Remove 19 screws and lift off heater duct cover.
12.Slacken vent flap trunnion fixing, release air
distribution control cable and remove from
heater duct.
13.Check condition of foam sealant on heater duct
cover and renew if necessary.

HEATING AND VENTILATION
7
REPAIR Refit
14.Fit new control cable through heater duct cover
and secure to vent flap trunnion. Bend over
cable end to fully secure.
15.Fit heater duct cover.
16.Fit lower fascia panel assembly to fascia
bulkhead
See CHASSIS AND BODY, Repair,
lower fascia panel (heater duct) assembly.
17.Route control cable along fascia bulkhead to
contol lever assembly.
18.With control lever in closed position, secure
cable to clevis.
19.Fit outer cable retaining clip to lever assembly.
20.Fit lever assembly to side cover. Ensure screw
spacers are fitted between cover and lever
assembly.
21.Fit side cover to fascia cowl.
22.Fit control lever knobs.
23.Fit instrument panel
See INSTRUMENTS,
Repair, Instrument panel.
24.Fit steering column nacelleSee STEERING,
Repair, Steering column nacelle.
CONTROL CABLE AND BLOWER MOTOR SWITCH
Service repair no - 80.10.17 - Control cable
Service repair no - 80.10.22 - Blower motor switch
Remove
1.Disconnect battery.
2.From inside engine compartment, release outer
cable retaining clip at heater unit.
3.Slacken trunnion fixing and release inner cable
from heater unit flap lever.
4.Release 2 retaining clips securing control cables
to engine bulkhead and heater hoses.
5.Remove 4 screws securing instrument panel to
fascia cowl.
6.Pull instrument panel away from fascia and
disconnect speedometer cable to ease access to
control cable.
7.Remove 2 screws securing control lever
assembly to side of fascia panel cowl. Note
plastic screw spacers fitted between cowl and
lever assembly and retain.

80HEATING AND VENTILATION
8
REPAIR
8.Release lever assembly and disconnect 3
blower motor leads, noting their positions.
9.Pull control cable through bulkhead grommet
and out from instrument panel cowl.
10.Release retaining clip securing outer cable to
lever assembly.
11.Release inner cable from lever peg.
NOTE: If the blower motor switch is faulty
the complete lever assembly will have to
be renewed.
Refit
12.Fit new control cable to lever assembly peg.
13.Fit retaining clip to secure outer cable.
14.Reconnect blower motor leads.
15.Route cable to rear of instrument panel cowl,
along bulkhead and out through grommet into
engine compartment.
16.Fit lever assembly to panel cowl. Ensure screw
spacers are fitted between cowl and lever
assembly.
17.Fit instrument panel to fascia cowl.
18.With lever in closed position, fit control cable to
heater unit flap lever trunnion.
19.Secure outer cable with retaining clip.
20.Secure control cables to engine bulkhead and
heater hoses with retaining clips.
21.Reconnect battery.

AIR CONDITIONING
1
ADJUSTMENT GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable, but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.REMEDIAL ACTIONS
1.If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2.If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3.If suspected of being overcome by inhalation of
R134a vapour seek fresh air. If unconscious
remove to fresh air. Apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30°C, R134a should be
handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50°C.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car.