1996 LAND ROVER DEFENDER air condition

70BRAKES
2
OVERHAUL MASTER CYLINDER
Service repair no - 70.30.09
Before starting overhaul procedure refer to general
brake service practice
See Repair, General brake
service practice
.
Dismantling master cylinder
1.Disconnect battery and remove master cylinder
from servo
See Repair, Master cylinder.
2.Before commencing overhaul procedure
thoroughly clean master cylinder and inspect
outer surfaces for damage and condition, renew
complete assembly if necessary.
3.The reservoir is a push fit in master cylinder and
secured by seals. Carefully ease reservoir from
master cylinder by rolling it from seals as
illustrated.
4.Using soft jaws, one either side of master
cylinder flange and clamp flange in a suitable
vice. Remove water ingress 'O' ring seal from
master cylinder to servo flange and discard.
5.Hold outside of transfer housing with a suitable
pair of grips, carefully pull, while working pliers in
a backwards and forwards rocking motion to
ease housing off master cylinder, discard
housing and vacuum seal.
6.Withdraw 2 reservoir seals from master cylinder
and note their positions in inlet ports for
reassembly. Discard both seals.
7.Remove retaining ring and 'O' ring seal from
machined outer surface of master cylinder,
discard both seal and retaining ring.

BRAKES
3
OVERHAUL
8.Remove guide ring from mouth of master
cylinder which supports primary plunger
assembly and place to one side, this component
is not part of master cylinder service kit and is to
be refitted on assembly of unit.
9.Pull primary plunger assembly out of master
cylinder.
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
10.The secondary plunger assembly will remain at
bottom of master cylinder bore, plunger can be
easily expelled by tapping assembly on a piece
of timber until plunger appears at cylinder mouth,
carefully pull plunger from master cylinder.
11.If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
expel it from bottom of master cylinder bore and
discard.12.Clean all parts with Girling cleaning fluid or
unused brake fluid and place cleaned parts on to
a clean sheet of paper. Inspect cylinder bore and
plungers for signs of corrosion, ridges and score
marks. Provided working surfaces are in perfect
condition, new seals from a Girling Service
repair kit may be used.
Renewing secondary plunger seals
A.Springs
B.Seal retainer
C.Recuperating seal (primary cup)
D.Washer
E.'L' seal
13.Remove components above from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded and polished is required to
remove 'L' seal. DO NOT damage
secondary plunger.
14.Coat new seals in unused brake fluid and firstly
fit 'L' seal to plunger.
15.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.

74WHEELS AND TYRES
2
FAULT DIAGNOSIS FAULT - SYMPTOMS
Vibration through steering wheel
1.Check tyre pressures
See Repair, Tyre
Pressures
.
2.Check condition of tyres
See Tyre Wear Chart.
3.Check front wheel alignment
See STEERING,
Adjustment, Front Wheel Alignment
.
4.Check wheel balance
See Repair, Wheel
Balancing
.
NOTE: In the event that any apparent
vibration is not eliminated at this stage
See PROPELLER SHAFTS, Fault
diagnosis, Vibration Harshness
.
NOTE: In the event that any apparent
vibration is not eliminated at this stage, go
to steering Fault Diagnosis, Fault -
Symptom (Steering vibration, road wheel
shimmy/wobble)
See STEERING, Fault diagnosis,
Steering Faults
.
NOTE: Radial ply tyres have a flexible
sidewall, which produces a sidewall bulge
making the tyre appear under-inflated.
This is a normal condition for radial ply tyres. Do
not attempt to reduce this bulge by over-inflating
the tyre.
Key to illustration
1.Correct inflation.
2.Under-inflation.
3.Over-inflation.
4.Tread contact with road.

WHEELS AND TYRES
1
REPAIR REV: 05/99 GENERAL INFORMATION
WARNING: This is a multi-purpose vehicle
with wheels and tyres designed for both
on and off road usage. Only use wheels
and tyres specified for use on the vehicle.
The vehicle is equipped with tubeless 'S','T' or 'H'
rated radial ply tyres as standard equipment. The
tyres are of European metric size and must not be
confused with the "P" size metric tyres available in
North America.
Vehicle wheel sets, including spare wheel, must be
fitted with the same make and type of tyre to the
correct specification and tread pattern. Under no
circumstances must cross-ply or bias-belted tyres be
used.
For tyre specification and pressures
See GENERAL
SPECIFICATION DATA, Information, Wheels and
Tyres
.
Steel wheels
Tubeless tyres are mounted on 7.0 inch wide by 16
inch diameter steel wheels.
Alloy Wheels
Tubeless tyres are mounted on 7.0 inch wide by 16
inch diameter cast aluminium alloy wheels. The
surface has a paint finish covered with a clear
polyurethane lacquer. Care must be taken when
handling the wheel to avoid scratching or chipping the
finish.
The alloy wheel rim is of the asymmetric hump
type incorporating a safety hump to improve
location of the tyre bead in its seat. If difficulty is
experienced in fitting tyres to this type of rim
See
Tyre Fitting
.
WARNING: DO NOT fit an inner tube to an
alloy wheel.TYRE INSPECTION
Inspect tyres at weekly intervals to obtain maximum
tyre life and performance and to ensure compliance
with legal requirements. Check for signs of incorrect
inflation and uneven wear, which may indicate a need
for balancing or front wheel alignment,
See Fault
diagnosis, Tyre Wear Chart
, if the tyres have
abnormal or uneven wear patterns.
Check tyres at least weekly for cuts, abrasions, bulges
and for objects embedded in the tread. More frequent
inspections are recommended when the vehicle is
regularly used in off road conditions.
To assist tyre inspection, tread wear indicators are
moulded into the bottom of the tread grooves, as
shown in the illustration above.
When the tread has worn to a depth of 1.6 mm the
indicators appear at the surface as bars which
connect the tread pattern across the width of the tread
as shown in the illustration above.

74WHEELS AND TYRES
2
REPAIRREV: 05/99 When the indicators appear in two or more adjacent
grooves, at three locations around the tyre, a new tyre
must be fitted.
NOTE: DO NOT attempt to interchange
tyres, e.g. from front to rear, as tyre wear
produces characteristic patterns
depending on their position. If tyre position is
changed after wear has occured, the performance
of the tyre will be adversely affected.
NOTE: Territorial vehicle regulations
governing tyre wear MUST be adhered to.
WHEELS INSPECTION
Regularly check the condition of the wheels. Replace
any wheel that is bent, cracked, dented or has
excessive runout.
VALVES INSPECTION
Check condition of inflation valve. Replace any valve
that is worn, cracked, loose, or leaking air.TYRE PRESSURES
Maximum tyre life and performance will be
obtained only if tyres are maintained at the correct
pressures.
Tyre pressures must be checked at least once a week
and preferably daily, if the vehicle is used off road.
The tyre inflation pressure is calculated to give the
vehicle satisfactory ride and steering characteristics
without compromising tyre tread life. For
recommended tyre pressures in all conditions
See
GENERAL SPECIFICATION DATA, Information,
Wheels and Tyres
.
Always check tyre inflation pressures using an
accurate gauge and inflate tyres to the
recommended pressures only.
Check and adjust tyre pressuresONLYwhen the
tyres are cold, vehicle parked for three hours or more,
or driven for less than 3.2 km (2 miles) at speeds
below 64 km/h (40 mph). Do not reduce inflation
pressures if the tyres are hot or the vehicle has been
driven for more than 3.2 km (2 miles) at speeds over
64 km/h (40 mph), as pressures can increase by 0.41
bars (6 lb/in
2) over cold inflation pressures.
CheckALLtyre pressures including the spare. Refit
the valve caps as they form a positive seal and keep
dust out of the valve.

74WHEELS AND TYRES
4
REPAIR Static balance
Wheel tramp
A- Heavy spot.
B- Add balance weights here.
C- Centre line of spindle.
Static balance is the equal distribution of weight
around the wheel. A statically unbalanced wheel will
cause a bouncing action called wheel tramp. This
condition will eventually cause uneven tyre wear.Dynamic balance
Wheel shimmyA- Heavy spot.
B- Add balance weights here.
C- Centre line of spindle.
Dynamic balance is the equal distribution of weight on
each side of the centre line so that when the wheel
spins there is no tendency for side to side movement.
A dynamically unbalanced wheel will cause wheel
shimmy.

HEATING AND VENTILATION
1
DESCRIPTION AND OPERATION HEATING AND VENTILATION SYSTEM
Description
The heating and ventilation system is standard on all
models. Air conditioning is an optional system which
provides fully integrated climate control for the vehicle
interior.The heater assembly, comprising a matrix housed in a
distribution unit and a variable speed blower motor, is
located on one side of the engine compartment and
attached directly to the fascia bulkhead.
The heating controls are positioned on the outside of
the instrument binnacle and cable linked to
mechanical flaps in the distribution unit.
Heater assembly
1.Heater distribution unit
2.Fixings, heater to fascia bulkhead
3.Heater matrix
4.Blower motor housing
5.Circlip, impeller to blower motor
6.Impeller
7.Resistor unit and harness connector8.Fixings, blower motor mounting plate
9.Mounting plate, blower motor
10.Blower motor
11.Fixings, blower motor to mounting bracket
12.Temperature flap, air flow to heater matrix
13.Air flap, air supply to plenum chamber (heater
duct)

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.