1996 LAND ROVER DEFENDER air conditioning

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.

AIR CONDITIONING
15
REPAIR EVAPORATOR - RH DRIVE
Service repair no - 82.25.20
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit - RH drive.
2.Suitably support unit on a bench.
3.Remove sealant and release thermostat probe
from low pressure pipe.
4.Remove 2 screws securing blower motor cover
to main casing.
5.Withdraw cover sufficiently to release motor
Lucar connector and earth eyelet. Remove
cover.
6.Unscrew top adaptor pipe from heater matrix.
7.Remove 18 fixings securing top cover to main
casing and heater/cooler support frame.
8.Carefully break sealing compound around edge
of joint seam and remove top cover from main
casing.
9.Lift out heater matrix.
10.Remove 2 screws securing back of evaporator
to support frame.
11.From underneath, remove 2 nuts and washers
securing evaporator matrix to base of casing.
12.Lift evaporator matrix from casing, complete with
side plates.
13.Remove side plates
14.Clean sealing compound from all joint seams of
main casing and top cover.
NOTE: The evaporator matrix is supplied
complete with the expansion valve.
However, a faulty expansion valve can be
serviced separately,
See Expansion valve - RH
drive.
Refit
15.Locate side panels to new evaporator lower
fixing studs.
16.Fit evaporator, with side plates, into main casing.
Ensure both studs are located through bottom of
casing and secure.
17.Apply sealing compound around joint seam of
main casing.
18.Fit top cover to main casing.
19.Fit thermostat probe to to low pressure pipe and
apply sealant.
20.Fit top adaptor pipe to heater matrix.
21.Fit Lucar connector and eath eyelet to blower
motor.
22.Fit blower motor cover.
23.Fit heater/cooler unit assembly into engine
compartment
See Heater/cooler unit.

82AIR CONDITIONING
16
REPAIR EXPANSION VALVE - RH DRIVE
Service repair no - 82.25.01
Remove
1.Remove evaporator
See Evaporator - RH
drive.
2.Unscrew union securing pressure sensor to low
pressure pipe.
3.Release spring clip securing temperature sensor
to low pressure pipe.
4.Unscrew union and remove expansion valve
from evaporator high pressure pipe.
5.Remove high pressure pipe from expansion
valve.
6.Discard all pipe connection 'O' rings.
Refit
7.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
8.Fit high presssure pipe to new expansion valve.
9.Fit expansion valve to evaporator high pressure
pipe.
10.Secure temperature and pressure sensors to low
pressure pipe.
11.Fit evaporator
See Evaporator - RH drive.

AIR CONDITIONING
17
REPAIR HEATER MATRIX - RH DRIVE
Service repair no - 82.25.19
Remove
1.Remove heater/cooler unit
See Heater/cooler
unit - RH drive.
2.Suitably support unit on a bench.
3.Remove sealant and release thermostat probe
from low pressure pipe.
4.Remove 2 screws securing blower motor cover
to main casing.
5.Withdraw cover sufficiently to release motor
Lucar connector and earth eyelet. Remove
cover.
6.Unscrew top adaptor pipe from heater matrix.
7.Remove 18 fixings securing top cover to main
casing and heater/cooler support frame.
8.Carefully break sealing compound around edge
of joint seam and remove top cover from main
casing.
9.Lift out heater matrix.
10.Clean sealing compound from all joint seams of
main casing and top cover.
Refit
11.Locate heater matrix in main casing.
12.Apply sealing compound around joint seam of
main casing.
13.Fit top cover to main casing.
14.Fit adaptor pipe to heater matrix.
15.Fit thermostat probe to to low pressure pipe and
apply sealant.
16.Fit Lucar connector and eath eyelet to blower
motor.
17.Fit blower motor cover.
18.Fit heater/cooler unit assembly into engine
compartment
See Heater/cooler unit.

82AIR CONDITIONING
18
REPAIR RESISTOR, BLOWER MOTOR - LH DRIVE
Service repair no - 82.20.26
Remove
1.Remove multi-plug from resistor.
2.Remove blower motor relay from connecting
block to gain access to fixing screw.
3.Remove screw and release relay connector
block. Retain relay in connector block.
4.Remove screw and detach air conditioning 30
amp fuse bracket from resistor.
5.Lift resistor unit from top cover.
Refit
6.Locate resistor unit in top cover.
7.Fit fuse bracket.
8.Fit blower motor relay connector block and relay.
9.Fit resistor multi-plug.RESISTOR, BLOWER MOTOR - RH DRIVE
Service repair no - 82.20.26
Remove
1.Remove multi-plugs from resistor.
2.Remove 2 screws securing resistor to wing
mounted block.
3.Withdraw resistor unit.
Refit
4.Secure resistor to mounting block.
5.Fit resistor multi-plugs.

WIPERS AND WASHERS
3
REPAIR WIPER MOTOR AND DRIVE RACK - VEHICLE
WITH AIR CONDITIONING, LH DRIVE
Service repair no - 84.15.20
Remove
1.Disconnect battery.
2.Remove wiper arms.
3.Remove single screw and remove fascia side
panel.
4.Remove 5 screws and withdraw instrument
panel as far as possible without straining wires
and cables.
5.Remove steering wheel
See STEERING,
Repair, Steering wheel.
6.Remove 2 screws at RH side and single screw
at LH side, inside instrument cowel, and
withdraw air conditioning panel and controls.
7.Release fascia panel LH support bracket.
8.Remove wiper motor cover finisher.

84WIPERS AND WASHERS
4
REPAIR
9.Remove door check strap cover and 3 screws
and withdraw wiper motor cover. If applicable,
disconnect switch multi-plugs and/or radio
speaker leads.
10.Disconnect wiper motor multi-plug.
11.Disconnect earth lead. (Not applicable on later
models)
12.Lift rubber sleeve from wiper motor and slacken
wiper motor to drive tube nut.
13.Remove 2 screws and release wiper motor
retaining strap, complete with mounting pad and
earth tag.
14.Pull wiper motor and drive rack clear of drive
tubes.Refit
15.Feed drive rack into drive tube until fully located
in wheel boxes.
16.Finger tighten drive tube nut.
17.Position motor mounting pad, fit retaining strap,
including earth tag and secure wiper motor
assembly.
18.Fully tighten drive tube nut and fit rubber sleeve.
19.Fit wiper motor multi-plug and earth lead to tag
on motor retaining strap.
20.Before fitting fascia panels, fit wiper blades,
reconnect battery and test wiper operation.
21.Refit fascia panels, noting that air conditioning
panel must be located and secured, on LH side,
with single screw, before instrument panel is
fitted.
22.Fit steering wheel
See STEERING, Repair,
Steering wheel.