Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							76CHASSIS AND BODY
38
REPAIR CANOPY ASSEMBLY
Service repair no - 76.61.11
Remove
1.Release side window velcro strips, each side
and top.
2.Unzip side window panels, at side only.
3.Release retaining batten from bottom channel.
4.Open rear door.
5.Release velcro strips each side of rear window.
6.Unzip rear window panel, down each side.
7.Release retaining bar, each end of rear window.
8.Release velro strips securing 2 flaps to roof bow.
9.Release 5 press studs securing flap around
centre roll-over bar.
10.Release 5 press studs securing straps around
rear roll-over bar.
11.Open front doors. Release 2 press studs
securing flaps, forward of centre roll-over bar.
12.Release 3 press studs securing flaps to frame
above front doors.
13.Release 3 canopy battens from channels at
each rear corner panel.
14.Release canopy batten from channel on each
side panel. 
						

							CHASSIS AND BODY
39
REPAIR
15.Remove screw securing side panel support rod
to vehicle body on each side.
16.Unhook top end of rods from support bars.
17.Remove top of side panels from groove in side
bar mouldings.
18.Withdraw suppotr rods from pockets in side
panels.
19.Release 2 press studs securing canopy to each
end of windscreen frame.
20.Pull canopy forward to release tension.21.Release batten from channel above windscreen
and ease dowwards to clear.
22.Ease front of canopy up between frame and
roll-over bar brackets.
23.Fold front of canopy onto roof.
24.Fold rear panel onto roof of canopy.
25.Fold each side panel onto roof.
26.Fold side and rear corner panels onto roof.
27.Remove canopy from vehicle.
28.Remove intermediate roof bow, retained by
spring loaded ball each side.
Refit
29.Lubricate spigots and fit intermediate bow to
cant rails.
30.Position canopy across centre roll-over bar and
roof bow.
31.Unfold canopy, position loosely over roll-over
bars and centralise.
32.Pull forward and position retaining batten
between windscreen frame and roll-over bar.
33.Ease batten upwards, rotate and engage
channel, press ends down and fully into channel.
34.Fasten front of canopy with press studs.
35.Pull canopy to tension over rear roll-over bar.
36.Fasten press studs securing canopy to rear
roll-over bar.
37.Feed cut-out in top of side panel into grove
around roll-over bar moulding.
38.Fasten press studs securing front sides to
support bars.
39.Fasten press studs securing canopy to centre
roll-over bar.
40.Secure flaps to roof bow.
41.Fully tension straps securing canopy to rear
roll-over bar.
42.If side windows have been removed: Zip side
windows along top only.
43.Engage side window zips at each side, do up 50
mm, 2 in only. 
						

							76CHASSIS AND BODY
40
REPAIR 44.Pull down on rear panels and engage battens by
pressing firmly into place.
NOTE: Use a T handled hook to pull down
on the loops to ease batten engagement.
45.Fasten side window zips and secure velcro
strips.
46.Fit rear window retaining bar, fasten rear window
zips and secure velcro strips. 
						

							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
2
DESCRIPTION AND OPERATION HEATER OPERATION
The heater matrix, located in the distribution unit, is
connected to the engine cooling system. As coolant is
circulated continuously through the matrix, a selection
of heated or ambient air is controlled by two flaps
within the distribution unit.The temperature flap
controls the amount of ambient air to the heater
matrix, air being suppliedthrough a ducted vent on top of the vehicle front wing
to the blower motor (volute) housing. The blower
motor can be used to boost the air flow into the
distribution unit. The air flap controls the supply of
heated or ambient air from the heater unit into a
plenum chamber integeral with the vehicle fascia. Two
flaps in the plenum chamber (heater duct) distribute
the air flow to either the footwell vents or windscreen
demister vents.
Non air conditioning fascia shown
Heater controls
1. Temperature control
Move the lever downwards to increase air
temperature or up to decrease air temperature.
2. Air distribution control
Lever fully up - windscreen vents only.
Lever midway - footwell and windscreen vents.
Lever fully down - footwell vents.3. Blower motor fan speed control
Move the lever progressively downwards to increase
fan speed. With the control at O the fan is switched
off and the volume of air entering the passenger
compartment is solely dependent on ram effect when
the vehicle is moving forward. 
						

							HEATING AND VENTILATION
3
DESCRIPTION AND OPERATION Fresh air vents
Two fresh air vents are fitted in the windscreen frame
and are controlled independently of the vehicle
heating system. Each vent is operated separately.
To open a vent, push the lever to the right and then to
the required position. 
						

							HEATING AND VENTILATION
1
REPAIR HEATER UNIT
Service repair no - 80.20.01
Remove
1.Remove bonnet and disconnect battery.
2.Remove radiator bottom hose at radiator union
and drain cooling system.
See COOLING
SYSTEM, Adjustment, Drain and refill
3.Slacken clips and disconnect heater hoses at
heater box unions.
4.Remove outer cable securing clips.
5.Slacken trunnions and disconnect control cables
from heater vent flap levers.
6.Remove heater wiring harness securing loop.
7.Disconnect harness multi-plug.
8.Remove interior bulkhead trim.
9.Remove lower nuts and bolts securing the
heater unit to the bulkhead. If air conditioning is
fitted, remove evaporator.
See AIR
CONDITIONING, Repair, Evaporator
10.Slacken heater unit upper retaining bolts.
11.Manoeuvre heater unit, complete with blower
motor, clear of air inlet duct and remove from
engine compartment.
12.Remove sealing rubber.
For heater matrix removal.
See Heater matrix
For blower motor removal.See Blower motor
Refit
13.Smear a NEW sealing rubber with a suitable
impact adhesive and fit to heater unit.
14.Manoeuvre heater unit into position in engine
compartment, fit blower motor to air inlet duct
and locate upper fixing bolts.
15.Loosely fit lower fixing bolts to heater unit .
16.Fully tighten upper fixing bolts followed by the
lower fixings.
17.Refit interior bulkhead trim.
18.Secure wiring harness and reconnect multi-plug.
19.Fit control cables to vent flap trunnions and
secure with outer cable clips.
20.Connect heater hoses.
21.Fit radiator bottom hose and refill cooling
system.
See COOLING SYSTEM, Adjustment,
Drain and refill
22.If air conditioning is installed, fit evaporator.See
AIR CONDITIONING, Repair, Evaporator
23.Fit bonnet and reconnect battery. 
						

							80HEATING AND VENTILATION
2
REPAIR BLOWER MOTOR
Service repair no - 80.20.15
Remove
1.Remove heater unit.
See Heater unit
2.Remove 3 nuts securing angled bracket to
heater unit. Pivot bracket to remove from studs.
3.Remove 5 nuts securing blower motor assembly
to volute housing.
4.Disconnect harness connector and remove
blower motor from volute housing.
5.Release circlip and withdraw impeller from motor
drive shaft.
6.Remove 3 nuts securing blower motor to
mounting plate.
7.Remove blower motor.
8.Examine components for signs of wear and
renew as necessary.
Refit
9.Apply Bostik 1261 adhesive to mating faces of
mounting plate and blower motor.
10.Fit blower motor to mounting plate and secure
with nuts. Ensure rubber mountings are correctly
fitted.
11.Fit impeller to motor drive shaft and secure with
circlip.
12.Position blower motor assembly in volute
housing and secure with nuts. Fit angled bracket
to lower fixing.
13.Reconnect harness plug to resistor harness and
fit angled bracket to heater unit.
14.Fit heater unit.
See Heater unit
HEATER MATRIX
Service repair no - 80.20.29
Remove
1.Remove heater unit.
See Heater unit
2.Remove 3 nuts securing angled bracket to
heater unit. Pivot bracket to remove from studs.
3.Remove 14 screws and detach 2 matrix retaining
plates from heater unit base.
4.Remove 9 screws securing matrix top retaining
plate.
5.Withdraw heater matrix through top of heater
unit casing. 
						

							HEATING AND VENTILATION
3
REPAIR Refit
6.Fit foam rubber to heater matrix casing.
7.Position matrix in heater unit casing.
8.Check that both vent flaps operate correctly
without sticking.
9.Secure matrix top retaining plate.
10.Secure matrix bottom retaining plates.
11.Fit heater unit.
See Heater unit
RESISTOR UNIT
Service repair no - 80.20.17
Remove
1.Remove heater unit.
See Heater unit
2.Drill out 4 rivets securing resistor mounting plate
to top of volute housing.
3.Remove resistor and disconnect blower motor
plug from harness.
Refit
4.Apply Bostik adhesive to resistor mounting plate
and rivet to volute housing.
5.Reconnect blower harness motor plug.
6.Fit heater unit.
See Heater unit
HEATER CONTROL CABLE - TEMPERATURE
CONTROL
Service repair no - 80.10.05
Remove
1.Disconnect battery.
2.Remove 4 screws securing instrument binnacle
to fascia cowl.
3.Pull instrument binnacle away from fascia to
ease access to control cable at bulkhead.
4.Remove retaining screws and pull off air
distribution and temperature control lever knobs.
5.Remove 3 screws and detach side cover,
complete with control lever assembly. 
						

							80HEATING AND VENTILATION
4
REPAIR
6.Remove 2 screws securing control lever
assembly to side cover and remove cover.
Retain plastic screw spacers fitted between
cover and control lever assembly.
7.Remove bolt and release outer cable retaining
clip.
8.Slacken grub screw and release inner cable from
clevis.
9.From inside engine compartment: Release outer
cable retaining clip at heater unit.
10.Slacken trunnion fixing and release inner cable
from heater unit flap lever.11.Release 2 retaining clips securing control cables
to engine bulkhead.
12.Pull control cable through bulkhead grommet
and remove from vehicle.
Refit
13.Fit control cable to heater flap lever trunnion with
approximately 10 mm, 0.4 in of inner cable
protruding from trunnion. Fully tighten trunnion.
14.Secure outer cable with retaining clip.
15.Route control cable through sealing grommet
and along inside of engine bulkhead to fascia
binnacle.
16.Secure control cables to engine bulkhead 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.Fit instrument binnacle.
23.Reconnect battery.