Land Rover Defender 90 110 Workshop 1984 Rover Manual

							AIR CONDITIONING- L.H. & R.H. STEERING 1821 
COMPRESSOR Petrol model 
Removal , .I /:. . ./. m 
1. Place  the vehiclc  in a  ventilated  area away  from 
open  flames  and heat sources. 
2.  Stop  the engine  and  secure the bonnet  in an  open 
position. 
3.  Remove  the  caps from  the  compressor  service 
valves  and connect  the gauge  set for  evacuating. 
4. Evacuate  the system  as previously  described. 
5. Open fully (turn  anti-clockwise)  the compressor 
service  valves and disconnect  the gauge  set. Cap  all 
pipe  and valve  connections 
to prevent  dirt or 
moisture  entering the system. 
6. Remove  the  electrical connections to the 
compressor. 
-. V8 models  only 
4
-cylinder  Petrol only 9. Release the jockey  wheel  adjuster to enable  the 
10. Release  the tensioner on the  compressor  drive belt. 
11. Remove the  fixing bolt and swivel  the compressor 
and  bracket  assembly  to expose 
the bolt  which  is 
securing  the bracket. 
12. Remove  the bolt  and lift the  compressor  and 
bracket  clear and place 
on a bench. 
13.  Whilst  supporting  the compressor,  remove the five 
bolts  holding  the compressor  to the brackets. 
front 
drive  (fan) belt to be  removed. 
7. Shckcn all the ComPressor adjustment fixin@ and 
8. Remove the adjusting  and  pivot  fixings and the 
remove 
the drive  belt from the compressor. 
compressor from retaining bracket. 
Diesel  model 
8- 
ST1418M 
All engines 
14. No servicing  is recommended  to the compressor, 
therefore  a new  unit  must 
be fitted. 
15.  Reverse procedure  as appropriate  13 to 
9 and 6 to 3 
for 
V8 models  or 8 to 3 for 4-cylinder  models 
noting  the procedure  for adjusting the  compressor 
drive belts. 
17  
						

							El AIR CONDITIONING - L.H. & R.H. STEERING 
Refitting 
Drive  belt adjustment 
Diesel  only 
16. Ensure  all adjustment  bolts  associated  with the 
compressor  are slack. 
17. Alter  the position of the  compressor  to provide  a 
belt  tension  of 4
-6 mm (0.19-0.25  in). Secure all 
compressor  adjustment bolts  and recheck the 
tension. 
4-cylinder  Petrol only 
18. Ensure  all adjustment  bolts associated  with the 
compressor 
(1) and  the lower  pulley  pivot fixing  (2) 
are  slack. 
19. Adjust  the position  of the  lower  pulley  to give  a 
belt tension 
of 4-6 mm (0.19-0.25  in). 
20.  Tighten 
the pivot  bolt  and recheck the tension. 
21.  Alter  the position 
of the  compressor to provide  a 
22. Secure all compressor  adjustment bolts  and 
belt 
tension 
of 4-6 mm (0.19-0.25  in). 
recheck  the tension. 
1 
ST1409M 
24.  Alter  the  position of the compressor to provide a 
belt  tension  of 4-6 mm (0.19-0.25  in). Secure  all 
compressor  adjustment bolts  and recheck  the 
tension. 
25.  Ensure  the jockey  pulley  adjustment bolts are 
slack. 
26.  Alter  the position 
of the  jockey  pulley to give a belt 
tension 
of 4-6 mm (0.19-0.25  in).  Secure  the 
adjustment  bolts and recheck tension. 
ST1391 M 
ST 1401M 
CONDENSER FAN MOTORS 
Removal 
1. Open  and secure the bonnet. 
2. Release  the  six self  tapping  screws securing  the 
front  nose and grille  assembly, 
lift clear. 
3.  Disconnect  the electrical  leads to 
the fans. 
4. Remove  the blanking  caps from  the fan  centres. 
5.  Remove  the 
8 mm securing  nuts,  star  and  spring 
washers  from the fan blade  centres,  pull blade  from 
its respective  fan motor  shaft. 
6. Release the two  fan  motor retaining  bolts and 
remove 
the motor whilst  feeding  the fan motor 
through  the appropriate  aperture. 
Refitting 
V8 Petrol only 2. 7. Reverse  procedures 6 to 1 ensuring the fan supply 
wiring  is routed  and  securely clipped 
so that the 
f-y 
23. Ensure all adjustment  bolts associated  with the 
compressor 
are slack.  wiring 
does not foul the fan blades. 
18  
						

							AIR CONDITIONING- L.H. & R.H. STEERING 1821 
CONDENSER AND RECEIVER/DRIER 
Removal 
1. Place the vehicle in a well  ventilated  arca. 
2. Stop the engine,  open and secure the  bonnet. 
3. Remove the caps  from  the compressor  service 
valves.  Connect  the  gauge  set 
for evacuation,  and 
evacuate  as detailed  earlier. 
4. Having  evacuated  the air conditioning  system, 
open  fully (turn  anti
-clockwise)  the  compressor 
service  valves and disconnect  the gauge  set. 
Replace 
all caps  to valve connections. 
5. Release the four  top and  two side  fixings  securing 
the  grille  and nose  assembly and remove. 
6. Disconnect  the wires  at the  rear of the  horn, the  air 
conditioning  fan leads located  across 
the top of the 
fan  cowling 
frame and the electrical  connector to 
the receivddrier. 
7. Release the four  bolts  and large  packing  washers  ~ 
8. Remove 
the four  nuts securing  the fan cowling  to 
NOTE: L.H. steering vehicle illustrated on R.H. 
steering  vehicles the high  pressure  hose is on the side of 
the evaporator unit facing the engine, 
securing  the cowling to the  wing  sides. 
the  bottom bracket  and 
lift clear. 
9. Remove the two  bolts securing thc bonnet striker 
support  plate. 
13. Release  the  high pressure  pipe from  the receiver/ 
drier,  cap the pipc end connections. 
Condenser  removal only 
10. Release the  top air conditioning  hose and  cap  the 
ends 
to prevent  moisture  and dirt entering  the 
system. 
7 610 9 6 7 
7 
S 
14. Release  both air conditioning  pipes  from the 
condenser  extension  plate. Lift the condenser 
clear. 
Receiveddrier removal 
15. 
11. Lift  the condenser  from the bottom  mounting lugs 
and carefully  ease the condenser  forwards as far as 
possible. 
16. 
12. Release  the high  pressure  air conditioning  hose 
complete  with the sight 
glass, at the  evaporator 17. 
connection.  Cap the ends to prevent  dirt  or 
moisture  entering the system. 
.-‘.;t:, .I... -> : .p. 
Whilst supporting with suitable  spanners,  unscrew 
pipe  ends  to prevent  dirt 
or moisture  entering  the 
system. 
Release  the 
receiver/drier clamp  bolts and allow 
the  assembly 
to drop  clear of the condenser. 
Lift  the 
receiveddrier from the condenser  and 
discard. 
11 is NOT recommended  to refit  the old 
unit. 
19 
the b~tt~m tifii~fi to the ieceii;eii’diiei. “Lap the  
						

							1821 AIR CONDITIONING - L.H. & R.H. STEERING 
EVAPORATOR - LH steering models 
NOTE: It is only  necessary  to evacuate  the air 
conditioning  system  when  removing  the  evaporator 
matrix  or 
to change the  expansion valve. 
Removal 
5 1. Place  the vehicle in a  ventilated  area away  from 
2.  Stop  the  engine  and  secure  the  bonnet  in an  open 
open 
flames  and heat  sources. 
position. 
Refitting 
18. Reverse  procedures  17 to 15 using a new  receiver/ 
drier  unit. 
19. Connect  the high  prcssurc  pipe to the received 
drier.  Using two spanners  on each  union,  tighten 
the  union  noting  that 
the sight glass remains in the 
vertical  position. 
20.  Carefully  locate the  condenser  into position,  refit 
the fixings securing  the condenser to  the extension 
plate. 
Connect  and tighten  the  air conditioning  hose 
to 
the top  of the condenser.  Use two spanners on each 
union. 
21.  Refit 
the condenser to the bottom  bracket. 
22.  Place  the bonnet  striker support  plate  into 
position,  do 
not secure at this stage. 
23. 
Fit the  fan  cowling  support brackets.  It will  be 
necessary 
to lift thc bonnet  striker support  plate  to 
permit  the positioning  of the  fan cowling  assembly 
to  the  condenser mounting 
lugs. 
24. Secure  the steady  rods  and the lower condenser 
mounting bracket. 
Do not  tighten  the  bolts  at this 
stagc. Reconnect the  top horn electrical  leads. 
25.  Loosely 
fit the  four  bolts and distance  washers 
which  support 
the bonnet striker support plate  and 
fan  cowling  to the  wing  sides. 
26.  Tighten the  lower condenser  bracket bolts. 
27.  Adjust  the condenser  position 
with the bonnet 
striker support  bracket assembly to  obtain an equal 
distance  from 
the radiator.  Tighten the  four  side 
mounting  bolts. 
28. Tighten the four nuis and washers  which sccure the 
fan cowling mounting. 
29. Reconnect  the  electrical wiring for the  fan 
assemblies, 
horn and receiveddrier. 
30. Recheck the  security of all fixings. 
31.  Refit  the front  nose and grille  assembly  and secure. 
32.  Evacuate,  sweep and charge  the  air conditioning 
20 
system  as previously  described. 
Heater matrix and blower  motor only 
3. Remove  the caps  from  the compressor  service 
4. Disconnect  the  low pressure  valve from thc 
compressor  and  cap both  ends to  prevent  dirt or 
moisture  entering the system. 
5. Using  two  suitable  spanners remove the high 
pressure  pipe  from  the  evaporator  side. Cap both 
ends  to  prevent dirt 
or moisture  entering  the 
system.  valves 
and close  (turn  clockwise) fully. 
/-% 
>--. 
Evaporator matrix  and expansion valve only 
6.  Remove the caps  from  the Compressor  service 
valves  and connect  the gauge  set for evacuating. 
described. 
8. Open the  compressor  service valves and disconnect 
the  gauge  set. Cap  all pipes  and gauge connections 
9. Release  the fixings  and remove  the expansion  tank 
to  provide  access to the  air conditioning  high and 
low  pressure  pipes. 
7 r- .^^..^ +... &L,. -:.. -,.-,4:+:--:-* r.,r+om op *v,=.,,;n,,ci,, /. CVdLU41G LIIG U11 LUllUlllul~1~l~ 3ya~c.111 LLJ yncvnvuo~~ 
d- :- to prevent  dirt or moisture entering  the system. f, -::: k;d  
						

							AIR CONDITIONING - L.H. STEERING 
:.- 10. Whilst supporting  both  unions with suitable 
spanners  unscrew the high  and low pressure  air 
conditioning pipes 
to the evaporator.  Cap the pipe 
ends  and evaporator  inlets to prevent  dirt  or 
moisture  entering the  system. 
18. Remove the  screw,  releasing the relay connector 
block. 
19. All wiring on the  top  of the  evaporator  is now 
disconnected with the exception of the earth lead, 
this 
is disconnected when  the evaporator mounting 
block  is removed. 
20. Using  suitable  pipe clamps,  clamp  the inlet  and 
outlet  coolant  pipes at the  base 
of the  evaporator 
and  release  the  two  jubilee  clips and  detach,  or 
drain  the radiator. 
.. , 
* 
Evaporator unit 
11. Disconnect  the electrical  leads fcedine  the 
h 
82 
 
21. From inside  the vehiclc  remove the  front passenger 
carpet  and self tapping  screws which retain 
the 
toe-board. Remove the toe-board. 
compressor 
clutch cycling  switch. 
switch. 
and  withdraw  it. 
12. Detach the vacuum  pipes from  the  water valve 
13. Remove  the fixings  securing the water  valve  switch 22. Release two bolts, 
14. Remove  the  clip and  cable  connection  from  the 
evaporator  heater flap rod.  Use a new  clip 
on 
reassembly. 
15. Release  the nylon  cable retainer. 
16. Detach  the  heater  electric  supply  lead  at the 
17. Remove  the  relay from its connecting  block 
connecting 
block. 
revealing 
one self  tapping  screw. 
23. From inside  the  engine  compartment  remove the 
two  upper  evaporator  mounting  block bolts  fitted 
to  the  engine  bulkhead.  This also releases  the 
earthing  leads. 
24. Remove  the bolt securing  the angled bracket  at the 
front 
of the  evaporator  casing. 
21  
						

							IF1 AIR CONDITIONING - L.H. STEERING 
ST1416M 
e42 
45 
22  
						

							.::.::!,,, .. 25. Lift the evaporator  clear of the  vehicle  and place ,,).... ;.*. on a bench with a suitable support  underneath the 
case  to ensure  the heater  pipes are 
not damaged. 
26.  Release  the  nuts  and remove  the  bracket  from 
underneath the evaporator  casing. 
27. Remove  the wire  clip and detach the dump  valve 
located  underneath. 
28. Release  the  seven self tapping  screws securing  the 
outlet  duct and carefully  break  the sealing 
compound  around  the edge 
of the duct  and pull 
ducting plate  away from evaporator  body. 
29. Remove the  fifteen  screws located  around the 
cover seam,  Remove  the old  sealing  compound 
from  the body  and 
top cover. 
30.  Remove  the four  screws  and four nuts  from the top 
of the cover. 
31. From  the front of the unit  remove  the two  screws 
adjacent to 
the low pressure  pipe moulding. 
32.  At the  side 
of the unit remove  the two  screws . adjacent to the air intake  aperture. 
33.  Lift  the top  cover 
off whilst  feeding  the  blower 
motor  wiring  and air control  flap rod through their 
respective  apertures,  thus exposing  the blower 
motor,  heater matrix and  air  conditioning 
evaporator  matrix. 
.,I. . ..., . .. 
- ,. ... .. , .. .. 
Blower motor unit removal  only  Expansion 
valve removal 
43. Support  the  suction  pipe union with suitable 
spanners  and release. 
44.  Remove  the bleed  pipe  retaining  nut  from the 
suction  pipe. 
45.  Remove 
the spring  clip retaining  the expansion 
valve  sensor  pipe 
to the main  suction  pipe  which 
now 
rcleases the expansion  valve and high  pressure 
pipe.  Place  valve 
on bench  and  unscrew the high 
pressure pipe  from the expansion valve. 
46. Seal  and  cap all apertures;  discard all ‘0’ rings 
which  are renewed 
on assembly. 
Refitting 
47.  Reverse  procedures  46 to 11 noting that all threads, 
unions, 
‘0’ rings  are coated  with rcfrigerant oil 
prior  to fitting. 
NOTE: Depending  upon which  unit has been 
refitted  reverse the appropriate  procedures: 
Heater  Matrix  or Blower  Motor 
5 to 3 
Evaporator  Matrix or Expansion Valve 10 to 6 and 
then  charge  the air conditioning  system as 
previously  described with Refrigerant 
12. 
RESISTOR BLOCK 
Removal 34. Remove  the screws rctaining the  motor  unit to thc 
casing. 
35. Release  the three  bracket  retaining  screws  and 
withdraw  motor and impeller. 
36.  Detach 
the star  washer,  spring clip and  impeller. 
37. Remove  the  two nuts from  the  motor  shroud  and 
lift  clear. 
1. Stop  the engine  and secure  the bonnet in an open 
2.  Detach  the blower  motor wiring connector. 
3.  Remove  the self  tapping  screw and 
lift the resistor 
position. 
block 
out. . ,. 
HeatedEvaporator matrices  removal only 
38. Lift  the support  ptate and insulation  pad from  the 
matrix. 
39. From  the  bottom of the casing,  remove  the  three 
screws  adjacent  to the  dump  valve outlet, 
in 
addition  to the  screws  next to the heater  pipes. 
40. Lift the evaporator  and heater  matrices  together 
with  the supporting  frame  containing the air 
direction flap clear  of the  casing. 
41.  Detach  the evaporator  matrix by releasing  the four 
screws,  two at both  ends 
of the support bracket. 
42. Detach  the heater  matrix  by removing the self- 
tapping  screw. 
Refitting 
4. Reverse  procedures 3 to 1. 
23  
						

							I82 I AIR CONDITIONING - R.H. STEERING 
EVAPORATOR BLOWER MOTOR - RH Steering 
models 
Rem 
o v  a 1 
1. Open  and secure  the bonnet. 
2. Release  the  plastic tie  retaining  the  carburetter 
breather  pipe 
to the right hand  air intake elbow. 
3. Remove  the  pulsair pipe connected  to the  air 
intake  elbow. 
4. Remove  the right  hand air intake  elbow. 
5. Disconnect the clip  and  blower  motor wiring. 
6. Release  the blower  motor cover fixings  and 
separate  the casing  slightly  to allow  the  earth  and 
Lucar  connectors  to be  released. 
7. Remove  the cover  ensuring that  a mark is made  on 
the  casing  to indicate  the correct  positioning 
of the 
blower  motor when refitting. 
8. Release  the  five self-tapping  screws and  withdraw 
the  blower  motor and impeller.  It may  be necessary 
to  move  the low  pressure  air  conditioning  pipe 
aside  to provide sufficient  clearance. 
9. Remove the  centre  nut on the  impeller  and 
carefully  ease the impeller  from the blower  motor 
shaft. 
Refitting  Evaporator 
remove and refit 
- R.H. steering  models 
For removal of the blower  motor only,  see  section 
“Evaporator  Blower Motor”. 
NOTE:  It is only required  to evacuate  the air 
conditioning  system when removing  the evaporator 
matrix  or changing  the expansion  valve. 
Rem 
o v a I 
1. Place  the  vehicle in a ventilated  area  away  from 
2. Stop the  engine  and  secure  the  bonnet in an open 
3. Disconnect  the battery. 
4. Unscrew  the radiator drain-plug  and partially  drain 
5. Remove the air-cleaner. 
6. Remove  the  caps  from  the compressor  service 
open 
flames  and heat sources. 
position. 
the radiator. 
valves. 
Heater  matrix only 
7. Fully  close  (turn clockwise)  the high  pressure 
8. Fully  open  (turn anti-clockwise) the lalw pressure 
9. Slowly  disconnect  the low  prcssurc  pipe from  the 
valve. 
valve. 
compressor  rotor lock adaptor  plate. 
10. Remove  the plastic ‘0’ ring  from  the  rotor lock 
seal.  Cap and seal  both  unions  to prevent  dirt  or 
moisture  entering the system. 
pipe  to the upper engine  bracket. 
12. Remove the two  plastic  ties, securing  the insulation 
cover 
on the  high  pressure  pipe  and  remove the 
cover. 
13. Whilst  supporting  both unions  with suitable 6., 
.. 11 11. Release the p:zstic :is ~~~~ifig the !CW P~~SSE~P 
10. Reverse  procedures 9 to 1 ensuring  that all seals  spanners, unscrew the high  pressure  air 
24 
are replaced.  conditioning 
pipe from  the evaporator.  
						

							AIR CONDITIONING - R.H. STEERING 
r- L%+ Evaporator matrix and expansion valve  only 
14. Evacuate  the air conditioning  system as previously 
described. 
15. Open  (turn anti-clockwise) the compressor  service 
valves  and  disconnect  the gauge  set. Cap 
all pipes 
and  gauge connections  to prevent  dirt  or moisture 
entering  the system. 
16.  Remove  the  insulating  cover 
on the low  pressure 
pipe. 
17. Whilst  supporting  both unions  with suitable 
spanners,  unscrew the low  pressure  air 
conditioning  pipe from  the evaporator. 
18. Cap both  ends  to prevent  dirt or moisture  entering 
the  system. 
19. Remove  the two plastic  ties, securing  the insulation 
cover  on the  high  pressure  pipe  and  remove  the 
cover. 
20.  Whilst  supporting  both unions  with suitable  ~ 
spanners, 
unscrew the high  pressure  air 
:.,c*-..:‘ 0 *It ,A.. 
1 It I‘ 
conditioning pipe  from the evaporator. 
82 
Evaporator unit 
21.  Remove  the self  tapping  screw securing  the air 
22.  Disconnect  the two ‘Ronco’ thermostat  wires. 
23.  Disconnect  the two  heater  hoses from 
the side of 
the  evaporator  unit. 
24.  Remove  the  vacuum  pipe from  the water  valve 
switch. 
25.  Remove  the clip  and  cable  connection  from the 
evaporator  air  flap  rod.  Use a new  clip 
on 
reassem bly. 
control 
flap solenoid. 
26.  Disconnect  the blower motor wiring  connections.  27. 
Remove 
the screw  retaining  the blower  motor 
wiring  tot 
he blower  motor housing. 
28.  Remove 
the two  bolts  securing the blower  motor 
resistor  block to the  engine compartment. 
29.  Remove  the bolt  securing  the front  support 
brackct 
to the blower motor housing. 
30.  From 
inside the vehicle  rcmove the  front passenger 
carpet  and five  self tapping  screws which retain the 
toe
-box cover. 
31.  Release  the  four  bottom mounting  bracket  bolts, 
ensuring  that 
the spacing washers  from the two 
innermost  bolts are retrieved  from the engine 
bulkhead  side. 
32.  From  inside  the engine  compartment  remove the 
two  13 
mm upper  evaporator  mounting bracket 
bolts  fitted 
to the engine bulkhead. 
33.  Lift 
the evaporator  clear  of the  vehicle  and place 
on a bench  with  the blower  motor cover facing  up. 
34.  Turn  the  evaporator  unit around  and  remove 
thc 
fixings retaining the blower motor  housing duct. 
35.  Remove 
the “Ranco”  thermostat  from the top of 
the unit. 
36.  Remove  the seven  self
-tapping  screws securing thc 
top and bottom halvcs of the  unit togethcr. 
37.  Remove the eight screws from  the  right hand  side 
of  the  unit. 
38.  Peel  back 
the sponge  pad  on the  outlet  duct to 
expose  the last  retaining screw. Remove  the 
screw. 
39. Remove  the two  screws on the top  of the unit. 
40.  Remove  the  joint  sealant  around 
the seam  and 
separate  the two  halves 
of the evaporator  cover 
assembly 
. 
41.  Remove  the heater  matrix  from thc evaporator 
casing. 
25  
						

							I82 I AIR CONDITIONING - R.H. STEERING 
Evaporator matrix and Expansion  valve only 
42. Release  the screws  attached  to the  blower  motor 
retaining plate  and remove  the plate. 
43.  Remove  the blower  motor inner housing. 
44.  Remove the  bleed
-pipe retaining nut from the low 
pressure  pipe. 
45.  Remove  the  spring clip retaining  the expansion 
valve  sensor  pipe  to  the  low pressure  pipe  and 
remove  the expansion  valve and high  pressure 
pipe. 
46.  Unscrew  the high  pressure pipe from  the expansion 
valve. 
47.  Seal  and cap all pipes  and connections  to prevent 
dirt  or moisture  entering  the  system. Discard  all 
‘0’ rings,  which  are renewed on refitting. 
48. Release the  two nuts adjacent to the dump  valve. 
49. Remove  the two  evaporator  mounting screws from 
each side 
of the  casing. 
50. Release  the two uppcr evaporator  mounting 
bracket  screws and 
pull the bracket  away from the 
evaporator. 
51.  Lift  the evaporator  matrix from the casing  with 
thc 
two side plates and place  on a bench. 
+ 
Refitting 
52.  Reverse  procedures 51 to 21, ensuring  that all 
threads,  unions  and 
‘0’ rings are  coated  with 
refrigerant 
oil prior  to  fitting. Discard  all  old ‘0’ 
rings and  renew on refitting.  When reversing 
procedure 
31, ensurc that  the spacing  washers  are 
fitted 
to the  two innermost  bolts. 
NOTE: Depending  upon which component has been 
removed,  reverse  the appropriate  procedure  as 
follows: 
Evaporator  matrix  and  expansion  valve 
20 to 2 
Heater matrix 13 to 2. 
26