Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							AIR CONDITIONING
9
REPAIR EXPANSION VALVE
Service repair no - 82.25.01
Remove
1.Remove evaporator.
See evaporator
2.Using a backing spanner, loosen union nut and
remove high pressure pipe.
3.Discard O ring.
4.Pull insulation away from capillary tube coil and
low pressure pipe.
5.Loosen clip and withdraw capillary tube coil from
low pressure pipe.
6.Loosen capillary tube union and disconnect
union from low pressure pipe. Discard O ring.
7.Using a backing spanner, loosen union nut and
remove expansion valve from pipe. Discard O
ring.
Refit
8.Lubricate NEW O rings with refrigerant oil and
fit to pipe ends.
9.Fit expansion valve to pipe, DO NOT tighten
union nut.
10.Connect capillary tube and tighten union nut.
11.Position capillary tube coil on low pressure pipe
and secure with clip.
12.Wrap capillary coil and union with Prestite tape.
13.Connect high pressure pipe to expansion valve,
carefully align with low pressure pipe and tighten
union nut.
14.Tighten expansion valve union nut.
15.Fit evaporator.
See evaporator; Refit
16.Carry out system test.See Adjustment,
System test
BLOWER MOTOR ASSEMBLY
Service repair no - 82.25.14
Remove
1.Remove evaporator.
See evaporator
2.Move passenger seat fully rearward.
3.Position evaporator unit above centre console
and seat panel.
4.Disconnect Lucars (B and O wires) from blower
motor.
5.Remove screws securing blower units to casing.
6.Release blower unit flanges from casing, sealed
with sealant.
7.Disconnect Lucars from resistor unit.
NOTE: Wire positions: G, U and R wires.
8.Remove blower motor unit.
Do not carry out further dismantling if component
is removed for access only.
9.Remove screws securing resistor unit to blower
motor. Note alignment of resistor unit.
10.Remove resistor unit and bracket.
11.Fit resistor unit to blower motor. 
						

							82AIR CONDITIONING
10
REPAIR Refit
12.Clean sealant from blower flanges.
13.Apply a bead of Silicone Sealant around each
blower flange.
14.Connect Lucars to resistor unit in correct order.
15.Position blower flanges on evaporator casing
and secure with screws.
16.Connect Lucars (B and O wires) to blower motor.
17.Fit evaporator.
See evaporator
18.Carry out system test.See Adjustment,
System test
EVAPORATOR
Service repair no - 82.25.20
Remove
1.Disconnect battery negative lead.
2.Recovery refrigerant from air conditioning
system.
See Adjustment, Refrigerant
recovery recycling recharging
3.Remove fascia duct bezel.See fascia duct
bezel
4.Remove 3 nuts securing evaporator casing to
mounting bracket.
5.Disconnect drain tube from drain pipe on LH side
of casing.
6.Position 2 heater hoses to side of air intake tube.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant.
7.Using a backing spanner, loosen union nut from
evaporator return pipe and disconnect. Discard
O ring.
8.Using a backing spanner, loosen union nut from
evaporator feed pipe and disconnect. Discard O
ring.
CAUTION: Plug the connections.
9.Ease 2 evaporator studs from their rubber
bushes, release grommet from bulkhead,
withdraw pipes from aperture and position
evaporator unit on floor.
10.Remove screw securing harness P clip to rear
of casing.
11.Disconnect Lucar (B wire) from motor.
12.Disconnect Lucars (G, U, and R wires) from
resistor unit. 
						

							AIR CONDITIONING
11
REPAIR
13.Remove screw securing mounting bracket flange
to casing.
14.Remove screws securing each end of blower
flanges to upper casing.
15.Remove 6 screws securing upper to lower
casing.
16.Remove tape sealing air duct inside casing.
17.Release tape sealing pipes to casing.
18.Cut through sealant along casing joint and
gaskets.
19.Ease upper from lower casing and remove upper
casing.
20.Lift evaporator unit from lower casing.
Do not
carry out further dismantling if component is
removed for access only.
21.Using a backing spanner, loosen union nut from
pipe and remove high pressure pipe. Discard O
ring.
22.Loosen clip and withdraw capillary tube coil from
low pressure pipe and withdraw coil from pipe.
23.Loosen capillary tube union nut and disconnect
from low pressure pipe.Discard O ring.24.Using a backing spanner, loosen union nut and
remove expansion valve from pipe. Discard O
ring.
Refit
25.Lubricate NEW O rings with refrigerant oil and
fit to pipe ends.
26.Fit expansion valve to pipe, DO NOT tighten
union nut.
27.Connect capillary tube and tighten union nut.
28.Position capillary tube coil on low pressure pipe
and secure with clip.
29.Wrap capillary coil and union with prestite tape.
30.Connect high pressure pipe to expansion valve,
carefully align with low pressure pipe and tighten
union nut.
31.Tighten expansion valve union nut.
32.Position evaporator unit in lower casing, align
bracket and engage blower flange screws, DO
NOT tighten.
33.Position upper casing, engage lower casing
flange and secure with screws. Ensure mounting
bracket screw engages evaporator bracket.
34.Tighten blower flange screws.
35.Apply Silicone sealant to casing joint and
insulating tape to seal pipes to casing.
36.Apply sealing tape around air duct joint.
37.Position evaporator unit in footwell.
38.Connect multiplugs to compressor relays and
secure harness P clip.
39.Connect Lucars (G, U, and R) to resistor unit
and (B) to motor.
40.Lift evaporator, insert pipes into aperture and
engage mounting studs.
41.Connect drain tube to pipe.
42.Fit grommet into aperture.
43.Lubricate NEW O rings with refrigerant oil and
fit to
44.Carry out a functional check. joints.
45.Using a backing spanner, engage high pressure
pipe and tighten union nut.
46.Using a backing spanner, engage low pressure
pipe and tighten union nut.
47.Fit nuts and secure evaporator casing to
mounting bracket.
48.Fit fascia duct bezel.See fascia duct bezel
49.Evacuate and recharge air conditioning system.
See Adjustment, refrigerant recovery
recycling recharging
50.Reconnect battery negative lead.
51.Perform leak test on disturbed joints
52.Carry out system test.
See Adjustment,
System test 
						

							82AIR CONDITIONING
12
REPAIR WIRING HARNESS - SUPPLEMENTARY
Service repair no - 86.70.23
Remove
1.Remove evaporator.
See evaporator
2.Remove nut and release earth eyelet from
fender.
3.Disconnect multiplug from compressor fly-lead.
4.Remove 4 ties securing harness to air
conditioning hoses.
5.Remove tie securing harness to engine harness.
6.Above chassis front crossmember, disconnect
multiplug from condenser fan fly-lead.
7.Disconnect multiplug from trinary switch.
8.Release ties securing harness to pipes.
9.Remove 4 screws securing fusebox cover to
centre console.
10.Remove cover.
11.Disconnect multiplug from main harness.
12.Remove screw securing earth eyelet to fusebox
bracket.
13.Pull harness from between centre console and
bulkhead.
14.Remove grommet from harness.
15.Remove P clip from harness.
16.Extract harness from front of engine
compartment and pass through bulkhead into
footwell area. Remove air conditioning harness. 
						

							AIR CONDITIONING
13
REPAIR Refit
17.Position harness in footwell and route harness
into engine bay, follow evaporator and receiver
drier hoses to receiver drier.
18.Fit grommet and P clip to harness.
19.Position harness between centre console and
bulkhead with multiplugs in fusebox area.
20.Secure earth eyelet to fusebox bracket.
21.Connect multiplugs to main harness.
22.Position switch harness to RH side of console, fit
fusebox cover and secure with screws.
23.Connect multiplug to trinary switch and
condenser fan fly-lead.
24.Secure earth eyelet to fender.
25.Connect multiplug to compressor fly-lead.
26.Secure harness to air conditioning hoses with
ties.
27.Secure harness to engine harness with tie.
28.Fit evaporator.
See evaporator
29.Perform leak test on disturbed joints
30.Carry out system test.
See Adjustment,
System test 
						

							AIR CONDITIONING
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Air conditioning Nm lbf ft
Compressor to mounting bracket 25..................................... 18
Compressor pipe flange bolts 10.......................................... 7
Receiver drier union bolts 6................................................ 4.5
Trinary pressure switch 11.................................................... 8
Pressure pipe union nuts - M16 14....................................... 10
Discharge pipe union nuts - M22 22..................................... 16
Suction pipe union nuts - M24 33.......................................... 24 
						

							WIPERS AND WASHERS
1
REPAIR WINDSCREEN WIPER MOTOR AND DRIVE RACK
Service repair no - 84.15.09
Service repair no - 84.15.12 - Wiper Motor
Remove
1.Disconnect battery.
2.Remove wiper arms.
See Windscreen wiper
arms
3.Remove fascia duct bezel.See AIR
CONDITIONING, Repair, Fascia duct bezel
4.Remove screw securing door check strap cover.
5.Remove door check strap cover.
6.Remove 3 screws and withdraw wiper motor
cover. Disconnect instrument illumination switch
multi-plug.
7.Disconnect multi-plug from wiper motor.
8.Disconnect wiper motor earth lead. (Not
applicable on 97 MY vehicles).
9.Lift rubber sleeve and slacken wiper motor to
drive tube nut.
10.Remove 2 screws and release wiper motor
retaining strap.
11.Fully unscrew tube nut.
12.Pull wiper motor and drive rack clear of tube and
retrieve mounting pad and earth tag.
Do not carry out further dismantling if component
is removed for access only.
13.Remove 4 screws and lift off gearbox cover.
14.Remove circlip and small plain washer securing
connecting rod.
15.Remove connecting rod and disconnect drive
rack.
Refit
NOTE: Use Ragosine Listate Grease to
lubricate gear wheel teeth, connecting rod
pin and cable rack.
16.Ensure large flat washer is in place over
crankpin.
17.Connect drive rack to pin and fit connecting rod
over crankpin and secure with small plain
washer and circlip.
18.Fit gearbox cover and secure with screws.
19.Feed wiper motor drive rack into tube until fully
seated.
20.Loosely fit drive tube securing nut.
21.Fit wiper motor securing strap and mounting
pad. Align motor and tighten fixing screws.
22.Fully tighten tube nut and fit rubber sleeve.
23.Reconnect earth lead and multi-plug.
24.Fit wiper blades.
See Windscreen wiper arms
25.Reconnect battery and test operation of wiper
motor and drive assembly. If necessary, adjust
position of wiper blades.
26.Fit instrument illumination switch multi-plug.
27.Fit cover and door check strap cover.
28.Refit fascia duct bezel.
See AIR
CONDITIONING, Repair, Fascia duct bezel 
						

							84WIPERS AND WASHERS
2
REPAIR WINDSCREEN WIPER ARMS
Service repair no - 84.15.01
Remove
1.Pull wiper arm away from windscreen.
2.Using a small screwdriver, hold back spring clip
which retains arm to spindle adaptor.
3.Pull wiper arm from splined adaptor.
Refit
4.Switch wiper motor to park position, with grub
screw retaining adaptor, uppermost.
5.Push arm on to adaptor ensuring that wiper
blade is just clear of windscreen surround
rubber.
6.Operate wipers and, if necessary, adjust position
of arms.WINDSCREEN WIPER/WASHER SWITCH
Service repair no - 84.15.34
For remove and refit procedure
See ELECTRICAL,
Repair, Windscreen wiper/washer switch
REAR SCREEN WIPER AND WASHER SWITCHES
Service repair no - 84.30.27 - Rear Screen Washer
Switch
Service repair no - 84.35.33 - Rear Screen Wiper
Switch
For remove and refit procedure
See ELECTRICAL,
Repair, Heated rear screen, rear wiper and washer
switches 
						

							WIPERS AND WASHERS
3
REPAIR WINDSCREEN WIPER WHEEL BOXES
Service repair no - 84.15.25
Remove
1.Disconnect battery.
2.Remove wiper arms.
See Windscreen wiper
arms
3.Remove wiper motor and drive rack.See
Wiper motor and drive rack
4.Remove instrument housing, fascia crash pad,
and ventilator grille panel.
5.Slacken steering column support rod lower
fixing.6.Remove steering column upper support fixing.
7.Slacken nuts to release back plates from LH and
RH wheel boxes.
8.Remove drive rack tubes.
9.Slacken grub screws and remove wiper arm
adaptors.
10.Remove LH and RH wheelbox spindle nuts.
11.Remove wheel box assemblies from vehicle. 
						

							84WIPERS AND WASHERS
4
REPAIR Refit
NOTE: During reassembly, all fixings
related to wiper motor and wheelboxes are
finger tightened only, until all components
are correctly aligned.
12.Fit wheelboxes to bulkhead and secure with
retaining nuts and washers.
13.Fit drive rack tubes to wheelboxes.
14.Apply grease to drive rack and wheelboxes.
15.Align wiper motor and mounting pad, secure with
retaining strap and tighten drive tube nut.
16.Fully tighten wheelbox back plate nuts.
17.Fully tighten both wheelbox spindle nuts.
18.Fit wiper arm adaptors and secure with grub
screw.
19.Before refitting panels fit wiper blades, connect
multi-plug and ground lead, reconnect battery
and check wiper operation.
20.If satisfactory, secure steering column upper and
lower fixings and tighten to correct torque.
21.Fit ventilator grille panel, fascia crash pad,
instrument housing and all other components
removed to gain access to wiper motor and
wheelboxes.REAR WIPER MOTOR
Service repair no - 84.35.12
Remove
1.With assistance, unscrew 3 retaining nuts and
remove spare wheel from rear door mounting
studs.
2.Lift wiper arm end cap to gain access to securing
nut.
3.Remove nut and withdraw wiper arm from drive
spindle.
4.Remove retaining nut, plain washer and rubber
washer securing wiper motor drive spindle to
door.
5.Remove 2 screws and remove cover from wiper
motor mounting bracket.
6.Disconnect wiper motor harness multi-plug.
7.Remove bolt, with rubber washer, and remove
wiper motor from rear door.