1996 LAND ROVER DEFENDER Workshop Manual

AIR CONDITIONING
3
REPAIR CONDENSER FAN AND MOTORS
Service repair no - 82.15.08
Remove
1.Disconnect battery.
2.Remove 6 screws and lift grille panel from
vehicle.
3.Disconnect fan motor multi-plugs and release
harness retaining clips.
4.Remove nut and washers and withdraw fan
blade from motor drive shaft.
5.Remove 2 retaining screws, release motor fan
from shroud support brackets and feed motor
multi-plug lead through appropriate aperture.
Refit
6.Feed motor lead through fan shroud.
7.Fit motor to fan shroud support brackets.
8.Reconnect fan lead multi-plug and secure with
retaining clips.
9.Fit fan blade to motor drive shaft.
10.Fit grille panel.
11.Reconnect battery.CONDENSER
Service repair no - 82.15.07
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 condenser fan motor lead
multi-plugs.
5.Disconnect receiver/drier dual pressure switch
multi-plug.
6.Disconnect condenser low pressure pipe at
compressor.
7.Disconnect high pressure hose/pipe at
evaporator.

82AIR CONDITIONING
4
REPAIR
8.Remove 4 bolts and large packing washers
securing fan cowling brackets to wing sides.
9.Remove 4 nuts securing fan cowling to lower
mounting bracket and lift complete assembly
from condenser.
10.Remove 2 bolts securing bonnet striker support
plate and cross braces to grille top panel.
11.Remove 2 bolts securing cross braces to front
wings.
12.Lift condenser, from bottom mounting lugs and
carefully ease forwards to clear top grille panel.
13.Lift condenser, complete with receiver/drier, from
vehicle taking care to clear high and low
pressure hose/pipes at side of radiator.
14.Disconnect condenser and receiver/drier pipes.
15.Remove clamp bolts and release receiver/drier if
a new condenser is to be fitted.
16.Discard all pipe connection 'O' rings. Cap or plug
all connections to prevent ingress of dirt and
moisture.Refit
17.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
18.Secure receiver/drier to mounting clamps.
19.Fit condenser and receiver/drier pipes.
20.Lower condenser into position ensuring high and
low pressure pipes are located between radiator
and front wing.
21.Secure cross braces and bonnet striker support
plate to top grille.
22.Secure cross braces to front wings.
23.Secure fan cowl assembly to lower mounting
bracket and front wings.
24.Fit high pressure pipe at evaporator.
25.Fit condenser low pressure pipe at compressor.
26.Connect multi-plug at receiver/drier dual
pressure switch.
27.Connect fan motor lead multi-plug.
28.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
29.Reconnect battery.
30.Fit grille panel.

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
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.