Defender 300Tdi (1996+). Manual — part 96
AIR CONDITIONING
7
REPAIR
EVAPORATOR - LH DRIVE
Service repair no - 82.25.20
Remove
1. Remove heater/cooler unit
See Heater/cooler
unit.
2. Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3. Release 3 nuts and remove mounting bracket
from underneath unit casing.
4. Remove 7 screws securing outlet duct to
heater/cooler unit.
5. Carefully break sealing compound around edge
of duct and pull ducting from unit.
6. Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
7. Remove 4 screws and 4 nuts from top of cover.
8. From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
9. At side of unit remove 2 screws adjacent to air
intake aperture.
10. Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
temperature probe which is inserted in
evaporator matrix through top cover.
11. Lift support plate and insulation pad from heater
matrix.
12. From bottom of unit casing, remove 3 screws
adjacent to dump valve outlet, and screws next
to heater matrix pipes.
82
AIR CONDITIONING
8
REPAIR
13. Remove all other fixings securing evaporator
and heater matrix support frame to unit casing.
14. Lift evaporator and heater matrices, complete
with support frame assembly, clear of casing.
Retain heater matrix pipe seal pad.
15. Remove 4 screws securing evaporator matrix to
support frame.
16. Withdraw evaporator matrix, complete with
expansion valve, from support frame.
17. Clean sealing compound from all joints of main
casing, top cover and outlet duct.
NOTE: The evaporator matrix is supplied
complete with the expansion valve.
However, a faulty expansion valve can be
serviced separately,
See Expansion valve.
Refit
18. Fit evaporator matrix in support frame.
19. Fit evaporator, heater matrix and support frame
assembly in casing. Ensure studs for lower
mounting bracket are located through bottom of
casing.
20. Apply mastic sealant around heater matrix pipes
to seal pipe apertures in casing. Fit seal pad
over pipes.
21. Fit 3 bottom fixings to secure to secure base of
support frame.
22. Fit all other fixings to secure support frame
assembly.
23. Locate heater matrix insulation pad and cover
plate.
24. Apply sealng compound around top edge of
main casing.
25. Feed blower motor wiring through top cover and
fit grommet.
26. Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
27. Apply sealing compound to joint face of blower
motor outlet duct.
28. Locate duct over blower motor outlet and secure
to casing.
29. Secure lower mounting bracket to retaining studs
on base of main casing.
30. Fit heater/cooler unit assembly in engine
compartment
See Heater/cooler unit.
AIR CONDITIONING
9
REPAIR
EXPANSION VALVE - LH DRIVE
Service repair no - 82.25.01
Remove
1. Remove heater/cooler unit
See Heater/cooler
unit.
2. Suitably support unit on a bench to prevent
damage to heater matrix pipes.
3. Remove 7 screws securing outlet duct to
heater/cooler unit.
4. Break sealing compound around edge of duct
and pull duct from unit.
5. Remove all fixing screws securing top cover
seam and cover sides to main casing.
6. Remove 4 screws and 4 nuts from top of cover.
7. Break sealing compound from unit casing and
top cover.
8. Lift off top cover, release grommet and feed
blower motor wiring and air flap operating rod
through respective apertures. Note thermostat
temperature probe which is inserted in top of
evaporator.
9. Release 2 clips securing expansion valve sensor
and lagging to low pressure pipe.
10. Unscrew union securing expansion valve to
evaporator high pressure pipe.
11. Remove expansion valve, complete with high
pressure pipe.
12. Disconnect high pressure pipe from expansion
valve.
13. Discard all pipe connection ’O’ rings.
14. Clean sealing compound from all joints of main
casing, top cover and outlet duct.
Refit
15. Coat unions, threads and new ’O’ rings with
refrigerant oil prior to reassembly.
16. Fit high pressure pipe to new expansion valve.
17. Fit expansion valve to evaporator pipe
connector.
18. Position valve sensor at low pressure pipe and
secure with lagging and clips.
19. Apply sealing compound around top edge of
main casing.
20. Feed blower motor wiring through top cover and
fit grommet.
21. Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
22. Apply sealing compound to joint face of blower
motor outlet duct.
23. Locate duct over blower motor outlet and secure
to casing.
24. Fit heater/cooler unit
See Heater/cooler unit.
82
AIR CONDITIONING
10
REPAIR
HEATER MATRIX - LH DRIVE
Service repair no - 82.25.19
Remove
1. Remove evaporator
See Evaporator.
2. Leaving evaporator in place, remove single
screw securing heater matrix pipe plate to base
of support frame.
3. Remove heater matrix and insulation pad.
Refit
4. Position insulation pad and fit heater matrix to
support frame.
5. Fit heater matrix and evaporator assembly
See
Evaporator.
BLOWER MOTOR ASSEMBLY- LH DRIVE
Service repair no - 82.25.14
Remove
1. Remove heater/cooler unit
See Heater/cooler
unit.
2. Remove 7 screws securing outlet duct to
heater/cooler unit.
3. Carefully break sealing compound around edge
of duct and pull ducting from unit.
4. Remove 15 screws located around cover seam.
Break sealing compound from unit body and top
cover.
5. Remove 4 screws and 4 nuts from top of cover.
6. From front of unit remove 2 screws adjacent to
low pressure pipe moulding.
7. At side of unit remove 2 screws adjacent to air
intake aperture.
8. Lift off top cover, release grommet and feed
blower motor wiring and air control flap rod
through respective apertures. Note thermostat
probe which is inserted in evaporator matrix
through top cover.
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