Defender (1993+). Manual — part 91

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 C O N D l T l O N l N G

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 a l l

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