Land Rover Defender Workshop Rover Manual

							CHASSISANDBODY
35
REPAIR
15.
Iffitted, remove 2screws, washers andnuts
securing auxiliaryswitchpaneltolower fascia
panel andswitch cover.
16. Withdraw switchpanelanddisconnect switch
leads.
17. Remove 2screws securing switchcoverto
parcel tray.
18. Remove fuseboxcover.
19. Models withhand throttle:
Remove fuseboxLHretaining screw.
Pivot fuseboxdown togain access tolower
inner hand throttle coverfixingscrew.
Remove 4screws andliftup hand throttle cover
from lower fascia panel.
20.Remove 2screws andremove bothfootwell
vents fromlower fascia panel.
21. Remove singlescrewanddetach doorcheck
strap cover fromLHand RHdoors.
22. Remove 3screws securing wipermotor coverto
fascia bulkhead.
23. Release locatingpinsfrom fascia panel, lower
wiper motor coverand,ifapplicable, disconnect
radio speaker leads.Retain wipermotor rack
cover. OnLHdrive vehicles, disconnect
multi-plugs fromrearofswitch panel.
24. Prise out2large and5small capfasteners
securing trimpanel toparcel shelfandfascia
bulkhead.
25. Carefully foldback trimpanel toclear fresh air
vent operating leversandremove panelfrom
parcel shelf.     
						

							76CHASSIS
ANDBODY
36 REPAIR
26.
Release demisthoseandliftparcel shelffrom
lower fascia panel(heater duct).Feedmain
harness leadsandplugs through aperture in
parcel shelf.
27. Remove parcelshelf.
28.Remove 7screws securing bottomedgeoflower
fascia paneltofascia bulkhead, notingposition
of both footwell coverretaining plates.
29. Remove bothretaining platesandlower footwell
covers.
30. Unscrew 2retaining boltssecuring topedge of
lower fascia paneltobulkhead.
31. With assistance, lowerfascia paneland,if
applicable, disconnect RHradio speaker leads.
32. Remove fasciapanelfromvehicle. Refit
33. Position lowerfascia paneltobulkhead,
reconnect RHspeaker leads,ifapplicable, and
secure topedge with2bolts.
34. Locate RHfootwell coverretaining plateunder
bottom edgeoffascia panelandsecure with3
screws.
35. Repeat operation forLH footwell coverretaining
plate.
36. Fitremaining lowerfascia panelfixingscrews.
37. Locate parcelshelf.Ensure allradio and
auxiliary switchpanelharness leadsandplugs
are fedthrough aperture inparcel shelf.
38. Fitdemist hosesintoheater ductoflower fascia
panel. Ensure flanges ofhose grommets are
correctly seated.
39. Fittrim panel andsecure withcapfasteners.
40. Reconnect LHspeaker leads,ifapplicable,
locate wipermotor coverpinsinlower fascia
panel andsecure wth3screws. Ensurewiper
rack cover iscorrectly seated.OnLHdrive
vehicles, reconnect multi-plugs torear ofswitch
panel.
41. Secure finisher towiper motor cover.
42. Fitdoor check strapcovers onboth sides.
43. Fitfootwell ventstolower fascia panel.
44. Models fittedwithhand throttle:
Fit hand throttle cover.
Secure LHside offuse box.
45. Fitfuse boxcover.
46. Fitauxiliary switchcovertoparcel tray,if
applicable.   
						

							CHASSISANDBODY
37
REPAIR
47.
Connect leadsandplugs toauxiliary switches
and clock.
48. Secure switchpaneltolower fascia paneland
switch cover.
49. Position radiohousing, ifapplicable, andfeed
radio multi- plug,aerial andspeaker leadsfrom
switch covertoradio housing.
50. Secure radiohousing totrim panel.
51. Fitradio connections andsecure radioin
housing.
52. Fitcrash padtofascia bulkhead.
53. Fitdemister ventsincrash pad.
54. Fitgrab handle tolower fascia panelandsecure
to crash pad.Refit Land Rover decal.
55. Connect multi-plugs torear screen, hazardand
interior lampswitches andfitswitch panelto
fascia panel.
56. Fitheater control cable
SeeHEATING AND
VENTILATION, Repair,Heatercontrol cable-
air distribution
.
57. Fitinstrument panel
SeeINSTRUMENTS,
Repair, instrument panel
.
58. Fitsteering columnnacelle
SeeSTEERING,
Repair, Steering columnnacelle
.
59. Fitsteering wheel
SeeSTEERING, Repair,
Steering wheel
.
60. Reconnect battery. FRONT
UNDERTRAY
Service repairno-76.11.81 -Front undertray
Service repairno-76.11.85 -Acoustic pad
Remove 1. Raise vehicle onramp.
2. Position supportunderchassis front
crossmember.
3. Lower ramptogive clearance betweenaxleand
undertray.
4. Remove 4nuts, disconnect propellershaftfrom
front axle, andmove aside.
5. Remove 2bolts securing undertray tochassis
front crossmember.
6. Remove nutsecuring undertray tobump stop
front fixing boltonboth sides.
7. Remove 2bolts securing sidesofundertray to
rear undertray.
8. Pull front undertray forwardstorelease flanges
from rearundertray.
9. Lower undertray toclear steering boxetc.and
manouvre rearwardsoveraxle.
10. Remove frontundertray.
11. Ifnecessary, remove8fasteners torelease
acoustic padfrom undertray.   
						

							76CHASSIS
ANDBODY
38 REPAIR
Refit
12. Ifapplicable, fitacoustic padtoundertray.
13. Fitundertray inposition, ensuring flangesare
correctly locatedinrear undertray.
14. Secure undertray tochassis frontcrossmember,
bump stopsandrear undertray. Tightenfixings
to
14 Nm (10lbf/ft).
15. Fitpropeller shafttofront axleandtighten nuts
to 47 Nm (35lbf/ft).
16. Raise ramptoremove chassis support.
17. Lower ramp. REAR
UNDERTRAY
Service repairno-76.11.80 -Rear undertray
Service repairno-76.11.82 -Acoustic pad
Remove 1. Raise vehicle onramp.
2. Remove 2bolts securing sidesofundertray to
front undertray.
3. Remove 2bolts securing rearundertray to
chassis crossmember brackets.
4. Remove boltsecuring undertray toRH side of
chassis.
5. Pull undertray rearwards torelease fromflanges
of front undertray.
6. Remove rearundertray.
7. Ifnecessary, remove7fasteners andrelease
acoustic padfrom undertray.
Refit 8. Ifapplicable, fitacoustic padtoundertray.
9. Fitundertray inposition, ensuring flangesoffront
undertray arecorrectly located.
10. Secure undertray tochassis crossmember, RH
chassis side,andfront undertray. Tightenfixings
to
14 Nm (10lbf/ft).
11. Lower ramp.  
						

							CHASSISANDBODY
39
REPAIR
ACCESS
PANEL-FRONT UNDERTRAY
Service repairno-76.11.85 -Access panel
Service repairno-76.11.83 -Acoustic pad
The access panelisprovided inthe front undertray to
enable fitmentofthe wading plugintotheengine
timing cover.
Remove 1. Raise vehicle onramp.
2. Remove 5bolts securing accesspaneltofront
undertray.
3. Remove accesspanel.
4. Ifnecessary, remove5fasteners andrelease
acoustic padfrom access panel.
Refit 5. Ifapplicable, fitacoustic padtoaccess panel.
6. Fitaccess paneltofront undertray, Tighten
fixings to
14Nm (10lbf/ft).
7.Lower ramp. ACCESS
PANEL-REAR UNDERTRAY
Service repairno-76.11.84
The access panelisprovided inthe rear undertray to
enable fitmentofthe wading plugortiming tool
LRT-12-044 inthe flywheel housing, andaccess to
the engine oilsump drainplug.
Remove 1. Raise vehicle onramp.
2. Rotate access panelanti-clockwise torelease
locking flanges.
3. Remove accesspanelfromundertray.
Refit 4. Locate access panelflanges inundertray
apertures.
5. Rotate panelclockwise tosecure inundertray.
6. Lower ramp.    
						

							HEATINGANDVENTILATION
1
DESCRIPTION
ANDOPERATION
HEATING
ANDVENTILATION SYSTEM
Description The heating andventilation systemisstandard onall
models. Airconditioning isan optional systemwhich
provides fullyintegrated climatecontrolforthe vehicle
interior. The
heater assembly, comprising amatrix housed ina
distribution unitand avariable speedblower motor,is
located onone side ofthe engine compartment and
attached directlytothe fascia bulkhead.
The heating controls arepositioned onthe outside of
the instrument binnacleandcable linked to
mechanical flapsinthe distribution unit.
Heaterassembly
1. Heater distribution unit
2. Fixings, heatertofascia bulkhead
3. Heater matrix
4. Blower motorhousing
5. Circlip, impeller toblower motor
6. Impeller
7. Resistor unitand harness connector 8.
Fixings, blowermotormounting plate
9. Mounting plate,blower motor
10. Blower motor
11. Fixings, blowermotortomounting bracket
12. Temperature flap,airflow toheater matrix
13. Airflap, airsupply toplenum chamber (heater
duct)   
						

							80HEATING
ANDVENTILATION
2 DESCRIPTION
ANDOPERATION
HEATER
OPERATION
The heater matrix(3),located inthe distribution unit
(1), see J6341, isconnected tothe engine cooling
system. Aswater iscirculated continuously through
the matrix, aselection ofheated orambient airis
controlled bytwo flaps within thedistribution unit.The
temperature flap(12) controls theamount ofambient
air tothe heater matrix, airbeing supplied through
aducted ventontop ofthe vehicle frontwing
to the blower motor(volute) housing (4).The blower
motor (10)canbeused toboost theairflow intothe
distribution unit.Theairflap (13) controls thesupply of
heated orambient airfrom theheater unitintoa
plenum chamber integeralwiththevehicle fascia.Two
flaps inthe plenum chamber (heaterduct)distribute
the airflow toeither thefootwell ventsorwindscreen
demister ventsasshown.
HEATER CONTROLS
1. Temperature control
Move thelever downwards toincrease air
temperature orup todecrease airtemperature.
2. Air distribution control
Lever fullyup-windscreen ventsonly.
Lever midway -footwell andwindscreen vents.
Lever fullydown -footwell vents. 3.
Blower motorfanspeed control
Move thelever progressively downwardstoincrease
fan speed. Withthecontrol at0 the fanisswitched
off and thevolume ofair entering thepassenger
compartment issolely dependent onram airwhen the
vehicle ismoving.  
						

							HEATINGANDVENTILATION
3
DESCRIPTION
ANDOPERATION
Fresh
airvents
Two fresh airvents arefitted inthe windscreen frame
and arecontrolled independently ofthe vehicle
heating system. Eachventisoperated separately.
Toopen thevents, pushthelever tothe right andthen
down tothe required position.   
						

							HEATINGANDVENTILATION
1
REPAIR
HEATER
UNIT
Service repairno-80.20.01
Remove 1. Remove bonnetanddisconnect battery.
2. Remove radiatorbottomhoseatradiator union
and drain cooling system
SeeCOOLING
SYSTEM, Repair,Drainandrefill cooling
system
.
3. Slacken clipsandremove heaterhosesat
heater boxunions.
4. Remove outercable securing clips.
5. Slacken trunnions andremove controlcables
from heater ventflaplevers.
6. Remove heaterwiringharness securing loop.
7. Disconnect harnessmulti-plug.
8. Remove interiorbulkhead trim.
9. Remove lowernutsandbolts securing the
heater unittothe bulkhead.
10. Slacken heaterunitupper retaining bolts.
11. Manoeuvre heaterunit,complete withblower
motor, clearofair inlet duct andremove from
engine compartment.
12. Ifexisting heaterunitisto be refitted, remove
sealing rubber.
For heater matrixremoval
SeeHeater matrix.
For blower motorremoval
SeeBlower motor.
Refit
13. Smear anew heater unitsealing rubberwitha
suitable impactadhesive andfitto heater.
14. Manoevre heaterunitintoposition inengine
compartment, fitblower motortoair inlet duct
and locate upperfixingbolts.
15. Loosely fitheater unitlower fixingbolts.
16. Fully tighten upperfixingbolts.
17. Fully tighten lowerfixings andrefitinterior
bulkhead trim.
18. Secure wiringharness andreconnect multi-plug.
19. Fitcontrol cablestovent flaptrunnions and
secure withouter cable clips.
20. Connect heaterhoses.
21. Fitradiator bottomhoseandrefill cooling system
SeeCOOLING SYSTEM,Repair,Drainand
refill cooling system
.
22. Fitbonnet andreconnect battery.    
						

							80HEATING
ANDVENTILATION
2 REPAIR
BLOWER
MOTOR
Service repairno-80.20.15
Remove 1. Remove heaterunit
SeeHeater unit.
2. Remove 3nuts securing angledbracket to
heater unit.Pivot bracket toremove fromstuds.
3.Remove 5nuts securing blowermotorassembly
to volute housing.
4. Disconnect harnessconnector andremove
blower motorfromvolute housing.
5. Release circlipandwithdraw impellerfrommotor
shaft.
6. Remove 3nuts securing blowermotorto
mounting plate.
7. Remove blowermotor.
8. Examine components forsigns ofwear and
renew asnecessary.
Refit 9. Apply Bostik 1261adhesive tomating facesof
mounting plateandblower motor.
10. Fitblower motortomounting plateandsecure
with 3nuts. Ensure rubbermountings are
correctly fitted.
11. Fitimpeller tomotor shaftandsecure withcirclip.
12. Position blowermotorassembly involute
housing andsecure with5nuts. Fitangled
bracket tolower fixing.
13. Reconnect harnessplugtoresistor harness and
fit angled bracket toheater unit.
14. Fitheater unit
SeeHeater unit. HEATER
MATRIX
Service repairno-80.20.29
Remove 1. Remove heaterunit
SeeHeater unit.
2. Remove 2nuts securing angledbracket to
heater unit.Pivot bracket toremove fromstuds.
3.Remove 14screws anddetach twomatrix
retaining platesfromheater unitbase.
4.Remove 9screws securing matrixtopretaining
plate.
5. Withdraw heatermatrixthrough topofheater
unit casing.