Land Rover Defender Workshop Rover Manual

							82AIR
CONDITIONING
4 REPAIR
8.
Remove 4bolts andlarge packing washers
securing fancowling brackets towing sides.
9. Remove 4nuts securing fancowling tolower
mounting bracketandliftcomplete assembly
from condenser.
10. Remove 2bolts securing bonnetstrikersupport
plate andcross braces togrille toppanel.
11. Remove 2bolts securing crossbraces tofront
wings.
12. Liftcondenser, frombottom mounting lugsand
carefully easeforwards toclear topgrille panel.
13. Liftcondenser, completewithreceiver/drier, from
vehicle takingcaretoclear highandlow
pressure hose/pipes atside ofradiator.
14. Disconnect condenserandreceiver/drier pipes.
15. Remove clampboltsandrelease receiver/drier if
a new condenser isto be fitted.
16. Discard allpipe connection Orings. Caporplug
all connections toprevent ingressofdirt and
moisture. Refit
17. Coat unions, threads andnew Orings with
refrigerant oilprior toreassembly.
18. Secure receiver/drier tomounting clamps.
19. Fitcondenser andreceiver/drier pipes.
20. Lower condenser intoposition ensuring highand
low pressure pipesarelocated between radiator
and front wing.
21. Secure crossbraces andbonnet strikersupport
plate totop grille.
22. Secure crossbraces tofront wings.
23. Secure fancowl assembly tolower mounting
bracket andfront wings.
24. Fithigh pressure pipeatevaporator.
25. Fitcondenser lowpressure pipeatcompressor.
26. Connect multi-plug atreceiver/drier dual
pressure switch.
27. Connect fanmotor leadmulti-plug.
28. Evacuate andrecharge airconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
29.Reconnect battery.
30. Fitgrille panel.  
						

							AIRCONDITIONING
5
REPAIR
RECEIVER/DRIER Service
repairno-82.17.01
Remove 1. Disconnect battery.
2. Recover refrigerant fromairconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
3.Remove 6screws andliftgrille panel from
vehicle.
4. Disconnect receiver/drier dualpressure switch
multi-plug.
5. Disconnect highpressure pipeatreceiver/drier.
6. Disconnect bottomunionatcondenser.
7. Remove retaining boltsandopen clamps.
8. Release receiver/drier fromcondenser and
discard. Itis NOT recommended torefit oldunit.
9. Discard allpipe connection Orings. Caporplug
all connections toprevent ingressofdirt and
moisture.
Refit 10. Coat unions, threads andnew Orings with
refrigerant oilprior toreassembly.
11. Secure newreceiver/drier inretaining clamp.
12. Fitreceiver/drier bottomunionconnector at
condenser.
13. Fithigh pressure pipetoreceiver/drier.
14. Fitpressure switchmulti-plug.
15. Evacuate andrecharge airconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
16.Reconnect battery.
17. Fitgrille panel assembly. HEATER/COOLER
UNIT-L H DRIVE
Service repairno-82.25.21
Remove 1. Disconnect battery.
2. Recover refrigerant fromairconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
3.Remove expansion tankSeeCOOLING
SYSTEM, Repair,Expansion tank
togain
access toair conditioning highandlowpressure
pipes.
4. Disconnect highandlowpressure pipes.Discard
pipe connection Orings. Caporplug
connections toprevent ingressofdirt and
moisture.
5. Disconnect compressor clutchswitch multi-plug.
6. Remove pipeconnector fromvacuum switch.
7.Remove retaining clipand disconnect control
cable fromevaporator flapoperating rod.
8. Remove screwandrelease outercable retaining
bracket.     
						

							82AIR
CONDITIONING
6 REPAIR
9.
Remove plugconnector fromresistor.
10. Remove relayfromconnecting blocktogain
access tofixing screw.
11. Remove screwandrelease relayconnector
block. Retain relayinconnector block.
12. Remove screwanddetach airconditioning 30
amp fusebracket fromresistor. Refitboth
resistor retaining screws.
13.Using suitable pipeclamps, clampheater matrix
feed andreturn hoses atbase ofheater/cooler
unit. Release retaining clipsandremove hoses.
14. From inside vehicle remove frontpassenger
carpet, iffitted.
15. Remove retaining screwsandfoldback footwell
insulation.
16. Remove 2bolts securing heater/cooler unitlower
mounting brackettobulkhead.
17. From inside engine compartment remove2bolts
securing topheater/cooler unitmounting bracket
to engine bulkhead. Thisalsoreleases earthing
leads.
18. Remove boltsecuring supportbrackettofront of
heater/cooler casing. 19.
Liftheater/cooler unitclear ofair duct sealand
remove fromvehicle.
20. Discard allpipe connection Orings.
Refit 21. Coat unions, threads andnew Orings with
refrigerant oilprior toreassembly.
22. Position heater/cooler unitinengine
compartment andlocate withairduct seal.
23. Secure unittopand bottom mounting bracketsto
bulkhead andsupport brackettofront ofunit
casing. Fullytighten fixingboltswhen unitis
correctly positioned.
24. Fitfootwell insulation.
25. Reconnect heatermatrixhoses.
26. Fitairconditioning fusebracket, relayconnector
block, relayandresistor plugconnector.
27. Fitcontrol cabletoevaporator airflap operating
rod, using anew clip.
28. Fitpipe connector tovacuum switch.
29. Connect compressor clutchswitch multi-plug.
30. Connect highandlowpressure pipesto
evaporator.
31. Fitexpansion tank
SeeCOOLING SYSTEM,
Repair, Expansion tank.
32.Evacuate andrecharge airconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
33.Reconnect battery.   
						

							AIRCONDITIONING
7
REPAIR
EVAPORATOR
-L H DRIVE
Service repairno-82.25.20
Remove 1. Remove heater/cooler unit
SeeHeater/cooler
unit.
2. Suitably supportunitonabench toprevent
damage toheater matrixpipes.
3.Release 3nuts andremove mounting bracket
from underneath unitcasing.
4. Remove 7screws securing outletductto
heater/cooler unit.
5. Carefully breaksealing compound aroundedge
of duct andpullducting fromunit.
6. Remove 15screws located aroundcoverseam.
Break sealing compound fromunitbody andtop
cover.
7. Remove 4screws and4nuts from topofcover.
8. From frontofunit remove 2screws adjacent to
low pressure pipemoulding.
9. Atside ofunit remove 2screws adjacent toair
intake aperture.
10. Liftofftop cover, release grommet andfeed
blower motorwiring andaircontrol flaprod
through respective apertures.Notethermostat
temperature probewhichisinserted in
evaporator matrixthrough topcover.
11. Liftsupport plateandinsulation padfrom heater
matrix.
12. From bottom ofunit casing, remove 3screws
adjacent todump valveoutlet, andscrews next
to heater matrixpipes.     
						

							82AIR
CONDITIONING
8 REPAIR
13.
Remove allother fixings securing evaporator
and heater matrixsupport frametounit casing.
14. Liftevaporator andheater matrices, complete
with support frameassembly, clearofcasing.
Retain heatermatrixpipesealpad.
15. Remove 4screws securing evaporator matrixto
support frame.
16. Withdraw evaporator matrix,complete with
expansion valve,fromsupport frame.
17. Clean sealing compound fromalljoints ofmain
casing, topcover andoutlet duct.
NOTE: Theevaporator matrixissupplied
complete withtheexpansion valve.
However, afaulty expansion valvecanbe
serviced separately,
SeeExpansion valve.
Refit
18. Fitevaporator matrixinsupport frame.
19. Fitevaporator, heatermatrixandsupport frame
assembly incasing. Ensurestudsforlower
mounting bracketarelocated through bottomof
casing.
20. Apply mastic sealant aroundheatermatrixpipes
to seal pipe apertures incasing. Fitseal pad
over pipes.
21. Fit3bottom fixingstosecure tosecure baseof
support frame.
22. Fitallother fixings tosecure support frame
assembly.
23. Locate heatermatrixinsulation padandcover
plate.
24. Apply sealng compound aroundtopedge of
main casing.
25. Feed blower motorwiring through topcover and
fit grommet.
26. Fittop cover tocasing. Ensurethermostat
temperature probeisinserted intop of
evaporator. Applymastic sealant toair flap
operating rodaperture.
27. Apply sealing compound tojoint face ofblower
motor outletduct.
28. Locate ductover blower motoroutletandsecure
to casing.
29. Secure lowermounting brackettoretaining studs
on base ofmain casing.
30. Fitheater/cooler unitassembly inengine
compartment
See Heater/cooler unit.  
						

							AIRCONDITIONING
9
REPAIR
EXPANSION
VALVE-L H DRIVE
Service repairno-82.25.01
Remove 1. Remove heater/cooler unit
SeeHeater/cooler
unit.
2. Suitably supportunitonabench toprevent
damage toheater matrixpipes.
3.Remove 7screws securing outletductto
heater/cooler unit.
4. Break sealing compound aroundedgeofduct
and pullduct from unit.
5. Remove allfixing screws securing topcover
seam andcover sidestomain casing.
6. Remove 4screws and4nuts from topofcover.
7. Break sealing compound fromunitcasing and
top cover.
8. Lift offtop cover, release grommet andfeed
blower motorwiring andairflap operating rod
through respective apertures.Notethermostat
temperature probewhichisinserted intop of
evaporator.
9. Release 2clips securing expansion valvesensor
and lagging tolow pressure pipe.
10. Unscrew unionsecuring expansion valveto
evaporator highpressure pipe.
11. Remove expansion valve,complete withhigh
pressure pipe.
12. Disconnect highpressure pipefrom expansion
valve.
13. Discard allpipe connection Orings.
14. Clean sealing compound fromalljoints ofmain
casing, topcover andoutlet duct.
Refit 15. Coat unions, threads andnew Orings with
refrigerant oilprior toreassembly.
16. Fithigh pressure pipetonew expansion valve.
17. Fitexpansion valvetoevaporator pipe
connector.
18. Position valvesensor atlow pressure pipeand
secure withlagging andclips.
19. Apply sealing compound aroundtopedge of
main casing.
20. Feed blower motorwiring through topcover and
fit grommet.
21. Fittop cover tocasing. Ensurethermostat
temperature probeisinserted intop of
evaporator. Applymastic sealant toair flap
operating rodaperture.
22. Apply sealing compound tojoint face ofblower
motor outletduct.
23. Locate ductover blower motoroutletandsecure
to casing.
24. Fitheater/cooler unit
SeeHeater/cooler unit.    
						

							82AIR
CONDITIONING
10 REPAIR
HEATER
MATRIX-L H DRIVE
Service repairno-82.25.19
Remove 1. Remove evaporator
SeeEvaporator.
2.Leaving evaporator inplace, remove single
screw securing heatermatrixpipeplate tobase
of support frame.
3. Remove heatermatrixandinsulation pad.
Refit 4. Position insulation padandfitheater matrixto
support frame.
5. Fitheater matrixandevaporator assembly
See
Evaporator.
BLOWER MOTORASSEMBLY- LHDRIVE
Service repairno-82.25.14
Remove 1. Remove heater/cooler unit
SeeHeater/cooler
unit.
2. Remove 7screws securing outletductto
heater/cooler unit.
3. Carefully breaksealing compound aroundedge
of duct andpullducting fromunit.
4. Remove 15screws located aroundcoverseam.
Break sealing compound fromunitbody andtop
cover.
5. Remove 4screws and4nuts from topofcover.
6. From frontofunit remove 2screws adjacent to
low pressure pipemoulding.
7. Atside ofunit remove 2screws adjacent toair
intake aperture.
8. Lift offtop cover, release grommet andfeed
blower motorwiring andaircontrol flaprod
through respective apertures.Notethermostat
probe whichisinserted inevaporator matrix
through topcover.   
						

							AIRCONDITIONING
11
REPAIR
9.
Remove screwsecuring blowermotormounting
bracket toside ofcasing.
10. Remove nutand washer securing blowermotor
housing topedestal mounting bracket.
11. Liftblower motorassembly fromcasing.
12.Remove 3screws andwithdraw blowermotor
and impellor fromhousing. Noteposition ofside
mounting bracketandspacing washers between
motor mounting andhousing.
13. Remove starwasher andwithdraw impellerfrom
blower motor.
14. Liftmotor fromplastic mounting.
15. Slacken retaining clipand remove 3support
brackets. Refit
16. Secure support brackets tonew blower motor.
Do not fully tighten clipatthis stage.
17. Insert motor intoplastic mounting andfit
impeller.
18. Locate spacing washers, sidemounting bracket,
and fitmotor andmounting intomotor housing.
19. Secure assembly tomotor housing andfully
tighten support bracketretaining clip.
20. Fitblower motorassembly inmain casing.
21. Apply sealing compound aroundtopedge of
main casing.
22. Feed blower motorwiring through topcover and
fit grommet.
23. Fittop cover tocasing. Ensurethermostat
temperature probeisinserted intop of
evaporator. Applymastic sealant toair flap
operating rodaperture.
24. Apply sealing compound tojoint face ofblower
motor outletduct.
25. Locate ductover blower motoroutletandsecure
to casing.
26. Fitheater/cooler unit
SeeHeater/cooler unit.    
						

							82AIR
CONDITIONING
12 REPAIR
BLOWER
MOTORASSEMBLY -R H DRIVE
Service repairno-82.25.14
Remove
1. Disconnect blowermotorwiring plugs.
2. Remove 2screws securing blowermotorcover
to main casing.
3. Withdraw coversufficiently torelease motor
Lucar connector andearth eylet. Remove cover.
4.Remove 6screws andwithdraw blowermotor
and impeller.
5. Remove retaining nutand washer andwithdraw
impeller fromblower motorshaft. Refit
6. Secure impeller onnew blower motor.
7. Fitblower motorassembly inmain casing.
8. FitLucar connector andearth eyelet toblower
motor.
9. Fitblower motorcoverandconnect wiringplugs.   
						

							AIRCONDITIONING
13
REPAIR
HEATER/COOLER
UNIT-R H DRIVE
Service repairno-82.25.21
Remove
1. Disconnect battery.
2. Recover refrigerant fromairconditioning system
SeeRefrigerant recovery,recycling,
recharging.
3. Release ties,remove insulation coverand
disconnect evaporatorlowpressure pipe.
4. Disconnect evaporatorhighpressure pipe.
5. Discard allpipe connection Orings. Caporplug
all connections toprevent ingressofdirt and
moisture.
6. Using suitable pipeclamps, clampheater matrix
feed andreturn pipesatheater/cooler unit.
7. Remove screwsecuring aircontrol flapsolenoid.
8. Disconnect 2leads fromthermostat.
9. Remove pipefrom water valvevacuum switch.
10. Remove retaining clipand disconnect control
cable fromevaporator flapoperating rod.
11. Remove screwandrelease outercable retaining
bracket. 12.
Disconnect blowermotorwiring plugsand
release harness retaining clipfrom housing.
13. Remove boltsecuring frontsupport bracketto
blower motorhousing. Ifnecessary, remove
blower motorresistor blocktofacilitate
operation.
14. From inside vehicle remove frontpassenger
carpet, iffitted.
15. Remove fixingscrews andfoldback footwell
insulation.
16. Remove 4bolts securing heater/cooler unitlower
mounting brackettobulkhead. Ensurespacing
washers fromtwoinnermost boltsareretrieved
from engine bulkhead side.
17. From inside engine compartment remove2bolts
securing topheater/cooler unitmounting bracket
to engine bullkhead.
18. Liftheater/cooler unitclear ofair duct sealand
remove fromvehicle.