Land Rover Defender Workshop 1993 Rover Manual

							CHASSIS AND BODY 
Striker adjustment 
NOTE:  Before  carrying  out adjustment  to the 
striker  ensure  that the dovetail  is correctly 
adjusted. 
1. Loosen  the striker  securing  screws. 
2.  Adjust  the striker  and retighten  screws. 
3. Close the door  and check for correct  latching 
with  the door 
lock. 
4. Carry  out further  adjustment  as necessary. If 
full adjustment  cannot be achieved  carry out 
the  following: 
5. Remove  the striker  and nut plate. 
6. Elongate  the holes  in the  body  metal  which  is 
sandwiched  between the striker  and nut plate. 
7. If interference  between the striker  and the 
dovetail  is evident 
it is permissible to lightly 
grind  the bottom 
of the  striker  casting. 
8. Refit the striker  and adjust  as necessary. 
Dovetail  adjustment 
1. Lift and hold  the lock handle  in the  open 
position  while opening  and closing  the 
door. 
2. Adjust the dovetail  guide as necessary to 
eliminate  lifting, dragging  or binding  as the 
dovetail  enters the guide. 
3.  Grease  can 
be used as an  aid  to adjustment. 
24 ADDITION: OCT 1993  
						

							HEATER/FAN UNIT 
Remove,  Overhaul 
and refit 
REMOVE  FROM VEHICLE 
1. Remove  bonnet and  disconnect battery. 
2.  Remove  radiator  bottom  hose  at radiator 
union  and drain  cooling  system. 
3. Slacken  and remove  the  heater hoses at 
heater  box  unions. 
4.  Remove  outer cable  securing  clips. 
5. Slacken and remove  control  cables  at the 
heater  box. 
6. Remove  heater wiring  harness securing loop. 
7. Disconnect harness  multi-plug. 
8. Remove interior bulkhead trim. 
HEATING  AND VENTILATION 
OVERHAUL 
Fan Motor  Assembly 
12. Remove  the nuts  securing  the  angled  bracket 
to the  heater  unit, and  remove the bracket. 
13. Remove  the  five  nuts  securing  the fan 
assembly  to the  heater  unit.  Unplug the 
connector  and remove  the  fan  assembly 
from 
the  heater unit. 
14.  Remove  circlip  holding the impeller  to the 
drive  shaft  and remove the  impeller. 
15. Remove the  three  nuts  securing  the  fan motor 
to  the  mounting  plate and release  the  motor 
from  the plate. 
9. Remove  lower nuts  and  bolts  securing  the 
heater unit 
to the bulkhead. 
10.  Slacken  heater unit upper  retaining  bolts. 
11.  Manoeuvre  heater unit clear  of engine  bay. 
REISSUED: FEB 1993 1  
						

							HEATING AND VENTILATION 
24. Check  that flap  valves  operate  correctly and 
without  sticking. 
16.  Fit fan  motor  into  mounting plate,  apply  Bostik 
1261  adhesive 
to mating  faces,  and  secure  25.  Refit top cover  and rivet  into  place. 
with  the  three  nuts. 
17. Refit impeller  to fan  drive  shaft and fit circlip. 
18. Refit fan assembly to casing  and secure  with 
the  five  nuts.  26. 
Drill out  the  four  rivets  retaining  the  resistor 
19. Plug in connector to resistor  harness  and refit  mounting plate,  and lift out  plate  with resistor. 
angled  bracket.  27.  Apply  Bostik  adhesive to  resistor plate and 
secure 
in position  with rivets. 
Resistor  Unit 
Heater  Matrix 
REFIT TO VEHICLE 
20. Drill  out  rivets  holding  the  air duct  and  top 
cover  to the  casing.  (Three 
of the  rivets  are  28. Smear  heater unit sealing  rubber  with a 
concealed by  the rubber  seal).  suitable impact 
adhesive,  and locate 
to heater. 
29.  Place  heater  unit  into engine  bay  and 
manoeuvre into position  on bulkhead. 
30.  Loosely fit  lower  heater  unit nuts and bolts. 
31.  Tighten heater  unit  upper  securing bolts. 
32.  Tighten lower  nuts  and bolts. 
33.  Refit interior  bulkhead  trim. 
34.  Locate  heater  wiring  harness  into securing 
loop, and tighten  nut. 
35.  Connect  harness multi
-plug. 
36.  Refit  control  cable  outer  clip  and  inner  cable 
37.  If  necessary,  prime  heater  matrix with coolant 
pinch bolts. 
mixture. 
38.  Connect  hoses 
to heater unit  and  tighten hose 
clips. 
39.  Refit  radiator  bottom  hose  and refill  cooling 
system  with the  required  anti
-freeze 
concentration  or corrosion  inhibitor. 
40. Refit bonnet. 
41. Connect  battery,  start engine,  and  check for 
42.  After  engine  has  cooled check coolant  level  in 
the  expansion  tank and  radiator.  Top  up 
if 
21. Lift off cover,  air duct  and seal. 
22.  Lift heater  matrix out  of casing.  leaks. 
23.  Fit foam  rubber  to  heater  matrix casing  and 
position matrix 
in casing.  necessary. 
2 REISSUED: FEB 1993  
						

							AIR CONDlTlONlNG 
AIR  CONDITIONING  DEFENDER 110  DO 
NOT 
- leave  refrigerant drum without its 
General  Service Information - carry refrigerant  drum inside a 
INTRODUCTION - subject  refrigerant  drums to high 
Before any component of the air conditioning  system - weld or steam clean near an air 
is  removed,  the system  must be depressurised.  conditioning  system. 
When 
the component  is replaced,  the  system  must - expose eyes to liquid  refrigerant 
be  evacuated 
to remove  all traces  of old  refrigerant ALWAYS wear  goggles 
and  moisture.  Then  the  system must be recharged 
- discharge  refrigerant  vapour into an 
with new refrigerant.  area  with 
an exposed flame or into  an 
Any service  operation  that requires  the  loosening of engine  intake.  Heavy Concentrations 
a  refrigerant  line connection  should  be performed  of 
refrigerant  in  contact  with naked 
only  by qualified  service  personnel.  Refrigerant  flame produces  a toxic  gas. 
and/or 
oil will escape  whenever  a hose  or pipe is - allow  liquid  refrigerant to contact 
disconnected.  bright  metal, 
it will 
tarnish  metal  and 
All work involving  the handling  of refrigerant  requires  chrome  surfaces, 
and  combined with 
special  equipment,  a  knowledge of its  proper  use  moisture  can  seriously corrode all 
and  attention 
to safety  measures.  metal surfaces. 
Servicing 
equipment  PRECAUTIONS IN HANDLING  REFRIGERANT 
The  following  equipment  is required  for full servicing 
of the air conditioning  system. WARNING: Always wear safety  goggles  when 
Charging  trolley  opening refridgerant  connections. 
Leak  detector 
Tachometer  (a) When  disconnecting  any pipe 
or flexible 
Safety  goggles  connection the system  must  be  discharged 
of 
Refrigerant charging line gaskets 
all pressure. Proceed cautiously,  regardless of 
Thermometer 
-20°C to -60°C  gauge  readings. Open  connections  slowly, 
Valve  Core Removers 
keeping  hands and face  well clear, 
so that no 
injury  occurs 
if there is liquid  in the  line. If 
SERVICING  MATERIALS pressure  is  noticed, allow it to bleed off 
Refrigerant:  Refrigerant 12, which  includes Freon (b)  Lines,  flexible  end  connections  and 
components must 
be capped  immediately  they 
are  opened 
to prevent  the  entrance  of 
CAUTION: Methychloride refridgerants must not moisture and dirt. 
be used. (c) Any  dirt or grease  on  fittings must be wiped 
Nominal  charge weight: 
1.09 kg (38 ozs). off with a clean  alcohol  dampened  cloth. Do 
Compressor oil: See  Recommended Lubricants.  not use  chlorinated  solvents  such as 
trichloroethylene. 
If dirt,  grease  or moisture 
PRECAUTIONS IN HANDLING  REFRIGERANT cannot be removed  from  inside the  pipes. they 
must 
be replaced with new pipes. 
The  refrigerant  used in the  air conditioning system is (d) All replacement  components and flexible  end 
Refrigerant 
12. and  is transparent  and colourless  in  connections  are  sealed. and should  only be 
both the gaseous  and liquid  state It has a  boiling  opened  immediately  prior to making the 
point  of -29.8°C  (-21.7°F)  at atmospheric  pressure  connection. 
and  at all  normal  pressures  and temperatures 
it (e) Ensure  the  components  are at room 
becomes  a  vapour. 
The vapour  is  heavier  than air,  temperature  before  uncapping, to prevent 
non
-flammable,  and non-explosive. It is  condensation  of moisture  from the air  that 
non
-poisonous  except  when in contact  with an open 
flame,  and  non
-corrosive  until it comes in contact  (f) Components  must  not  remain  uncapped for 
with water.  longer  than  fifteen minutes In the event of 
The  following  precautions in handling  Refrigerant 12 delay.  the caps must  be  replaced 
should be observed  at all  times. 
(g) Receiver/driers  must  never 
be left uncapped 
as  they  contain  Silica Gel crystals 
which will 
absorb  moisture  from the atmosphere A 
receiver/drier  left  uncapped  must be replaced 
and  not used 
heavy  cap 
fitted. 
vehicle. 
temperature. 
LINES 
slowly. 
12  or Arcton  12. 
enters. 
REVISED: OCT 1993  
						

							AIR CONDITIONING 
(h) The  compressor  shaft must not be rotated Evaporator 
until  the system  is entirely  assembled  and 
contains  a charge  of refrigerant.  Examine the refrigeration  connections  at the  unit. 
If 
(j) A new  compressor  contains an initial  charge of the system  should develop  a fault, or if erratic 
312,5  ml (11 UK fluid  ozs) of oil  when  operation is noticed, refer to the  fault  diagnosis 
received,  part of which 
is distributed  chart. 
throughout  the system  when 
it has been  run. 
The  compressor  contains a holding  charge of 
gas  when  received  which should  be retained 
until  the hoses  are connected. 
component  connected to the  system  to ensure 
optimum  dehydration  and maximum  moisture 
protection  of the  system. 
(I) 
All precautions  must be taken  to prevent 
damage 
to fittings  and connections.  Slight Stem type Service  valves allow for the isolation of 
damage  could cause  a leak  with  the high  the compressor  from other  parts of the system, 
pressures  used in the  system.  When these valves  are used  in conjunction  with the 
(m)  Always  use 
two spanners of the correct  size,  liquid 
line quick-disconnect  fittings, the three  major 
one  on each  hexagon,  when releasing  and assemblies 
of the system  can be removed  from the 
tightening  refrigeration  unions.  vehicle 
with a minimal loss of refrigerant.  In addition, 
(n)  Joints  and O rings  should  be coated  with 
it is possible  to remove  major assemblies for repair 
refrigeration  oil 
to aid correct  seating.  Fittings of components  which are not part  of the  refrigeration 
which  are not lubricated  with refrigerant  oil are  system, 
or provide  access to parts of the vehicle 
almost  certain  to leak.  which are obstructed  by the  air conditioning  system, 
(o) 
All lines  must be free of kinks.  The efficiency  without fully discharging  the system. A thorough 
of  the  system  is reduced  by a single  kink 
or understanding of the stem type service  valve is 
restriction.  necessary 
before undertaking  servicing 
or repair 
(p)  Flexible  hoses should  not 
be bent to a radius 
less  than  ten times 
the diameter of the  hoses. 
(q)  Flexible  connections  should not 
be within 50 
mm 
of the  exhaust  manifold. 
(r)  Completed  assemblies  must be checked  tor 
refrigeration  lines touching  sheet metal  panels. 
Any  direct  contact 
of lines and sheet transmits 
noise  and must  be eliminated. 
Service  valves 
There are two types of service  valves in operation: 
(k) The  receiver/drier  should be the  last  Stem and Schrader.  To identify  where the different 
operations  occur, stem type 
will be boxed. 
Stem  type 
involving the air conditioning  system. 
PERIODIC MAINTENANCE 
Routine servicing  apart from visual  checks,  is not 
necessary.  The visual  inspections  are as follows: 
Condenser 
1 servlce  port With a hose pipe or air  line. clean the face  of the 
2. Valve  stem 
condenser 
to remove 
flies. leaves  etc. Check  the 
3. Compressor 
port pipe  connections for signs of oil leakage. 
4. Valve seat 
Compressor 5. Hose  connector 
Check  hose connections 
for signs of oil leakage. 
Check  flexible 
hoses for swelling.  Examine the 
compressor 
belt for tightness and condition. 
Checking  the compressor  oil level  and topping
-up is 
only  necessary  after charging  the system 
or in the 
event 
of a  malfunction of the  system. 
Receiver/Drier  Stem 
type service  valve 
Examine  the sight  glass for bubbles  with the system 
operating.  Check connections 
for leakage. 
2 RE-ISSUED: FEB 1993  
						

							AIR CONDITIONING 
NOTE: A special wrench  should be used  to 
adjust  the valve  to prevent  damage  to the  stem. 
The  stem  type service  valve  has three  positions, the 
operation 
of which  is  explained as  follows. 
A. ON:  FULLY  ANTICLOCKWISE - Normal 
operating  position, and the  position  which  is 
used  for connecting  and disconnecting  the 
manifold  gauge  set, is the  on position.  The 
stem  is  turned  fully  anticlockwise.  This  seals 
the  service  gauge  port  from  receiving  any 
refrigerant flow. 
B.  MID  (Test)  POSITION - After the  service 
gauge  manifold  has been  installed  (the  valve 
stem  is  in the  on position), turn  the valve stem 
the  required  number  of turns  clockwise.  This 
will  put the  valve  stem  seat  midway  in the 
service  valve  and allow  full system  operation 
while  permitting  refrigerant  pressure 
to reach 
the  gauges. 
C.  OFF:  FULLY  CLOCKWISE - With  the  service 
valve  stem turned  fully  clockwise,  the  valve 
will  block  passage  of refrigerant  flow through 
the  system.  As  illustrated, the  refrigerant  flow 
to  or from  the compressor  (depending  on 
whether 
it is  high  side or low  side) is  blocked. 
WARNING:  NEVER operate  the air conditioning 
system  with the service  valves in the 
OFF 
POSITION,  it will cause severe  damage  to the 
compressor. 
REISSUED: FEB 1993 3  
						

							AIR CONDITIONING 
Schrader Type  B. OFF:  FULLY  CLOCKWISE - With the  service 
valve  stem  turned  fully  clockwise,  the valve 
These  are secured 
to the head  of the  compressor,  will 
block  passage  of  refrigerant flow through 
and  the suction  and discharge  flexible end  the  system. As illustrated,  the  refrigerant  flow 
connections  are secured  to  them by unions.  to 
or from the compressor  (depending  on 
The  service  valves are  identified  as suction  or low  whether 
it is  high side  or low  side) is  blocked. 
pressure,  and  discharge  or high  pressure.  Whilst 
they  are  identical in operation  they  are  not 
WARNING:  NEVER operate  the air conditioning 
interchangeable,  as the  connections  are of different system  with the service  valves in the OFF 
sizes. POSITION,  it will cause severe  damage to the 
The  valve  with  the  larger  connections  fits the  suction 
side. 
As  the  name  suggests,  these  valves are for service 
purposes,  providing  connections  to  external 
pressure/vacuum  gauges for  test  purposes.  In Where  Schrader  Valve  depressors are not fitted  to 
combination  with  charging  and  testing  equipment  the  Testing  equipment lines Valve  core removers 
they  are  used  to charge  the system with  refrigerant. 
Schrader  service valve  compressor. 
Valve 
Core Remover 
can be used. 
Valve  Core Removal 
The  use  of valve  core removers will facilitate 
servicing operations  and should be used  as follows: 
1.  Close  all valves  on the charging  trolley. 
2. Remove the  service  valve  cap  and seals  from 
the  valve core  remover. 
3. Withdraw  the  plunger as far  as possible  and 
connect the core  remover 
to the  service  valve. 
4. Connect the  hose to the core  remover. 
5.  Depress the  plunger  until it  contacts  the  valve 
core.  Unscrew  the  valve  until it 
is free. 
Withdraw the  plunger to  its full  extent. 
Service  valve  caps  must be  replaced  when service 
operations  are completed.  Failure  to replace  caps 
could  result  in refrigerant 
loss and  system failure. 
1. Valve  stem 
2.  Hose  connection 
3. Service valve 
4. Schrader  valve core 
5.  Compressor port 
NOTE: A special  wrench should be used  to 
adjust  the valve  to prevent  damage  to the  stem. 
The  Schrader  type service  valve  has two positions, 
the  operation  of which  is  explained  as follows 
A.  ON:  FULLY  ANTICLOCKWISE - Normal 
operating  position,  and  the position  which is 
used  for connecting  and  disconnecting  the 
manifold  gauge  set,  is the  on position.  The 
stem  is turned  fully  anticlockwise.  This  seals 
the  service  gauge port from  receiving  any 
refrigerant  flow. 
4 REISSUED:  FEB 1993  
						

							AIR CONDITIONING 
Key to Circuit Diagram 
AC1. System relay module  AC13. Refrigerant  pressure switches 
AC2.  Evaporator/heater  fan switch  AC14. Engine coolant  temperature  switch 
AC3.  Evaporator/heater  fan relay  module  AC15. Diode 
AC4.  Evaporator/heater  fan  AC16. Fuse in holder 
- 30  amp 
AC5.  Evap/heater  fan speed  resistor  AC17. Fuse in holder 
- 30 amp 
AC6.  A/C on/off  switch  AC24. Connectors  to 
MFI ECM 
AC7.  Condenser  fan relay  ST2. Terminal post starter  solenoid 
AC8.  Condenser  fans  ST5. Starter/ignition  switch 
AC9.  Compressor  relay module  B. 60 amp  fuse,  main  fuse box 
AC10.  Compressor  F14 
20 amp fuse,  main fuse box 
AC11.  Diode  F15 
5 amp fuse,  dash fuse box 
AC12.  Thermostat 
REISSUED:  FEB 1993 5  
						

							AIR CONDITIONING 
AIR CONDITIONING  BLOWER MOTOR AND CONTROL  SYSTEM DIAGNOSIS  
						

							AIR CONDITIONING 
Refrigeration System Fault Diagnosis 
For any  refrigeration  system to  function  properly all 
components 
must be  in good  working  order. The  unit 
cooling  cycle  and the  relationship  between  air 
discharge  temperature  and ambient  temperature  and 
pressures  at the  compressor  can  help 
to 
determine proper operation  of the  system. 
The  length  of any  cooling  cycle  is determined  by 
such  factors  as ambient  temperature  and humidity, 
thermostat  settng,  compressor  speed  and air 
leakage  into  the  cooled  area,  etc.  With  these  factors 
constant,  any sudden  incr ease  in the  length  of the 
cooling  cycle  would  be indicative  of abnormal 
operation 
of the  air conditioner. 
The  low and  high  side pressures  at the compressor 
will  vary  with  changing  ambient temperature, 
humidity,  cab  temperature 
and  altitude. 
The  following  conditions  should  be  checked  after 
operating the  system  for several minutes: 
1. All  high  side  lines and components  should  be 
warm  to the touch. 
2. 
All low side  lines  should  be cool to  the touch. 
3. Inlet  and  outlet  temperatures  at the 
receiver/drier  should  be  at the  same 
temperature  (warm). Any very  noticeable 
temperature  difference  indicates  a  blocked 
receiver/drier. 
4.  Heavy frost  on the  inlet  to the  expansion  valve 
may  indicate  a  defective  valve  or moisture 
in 
the  system. 
5. With  ambient  humidity  between 30% and 
60%,  compressor  pressures  and  evaporator 
air  discharge  temperature  should  fall  within 
the  general limits given 
in the table  below. 
REISSUED:  FEB 1993 7