Defender (1993+). Manual — part 97

AIR CONDITIONING

26.

Release the nuts and remove the bracket from

expansion valve and high pressure pipe

underneath the evaporator casing.

Place valve on bench and unscrew the high

27. Remove the wire

clip

and detach the dump

pressure pipe from the expansion valve.

valve located underneath.

46. Seal and cap all apertures; discard all ' O '

28.

Release the seven self tapping screws

rings which are renewed on assembly.

securing the outlet duct and carefully break
the sealing compound around the edge of the
duct and pull ducting plate away from
evaporator body.

47. Reverse procedures 11 to 46 noting that all

29. Remove the fifteen screws located around the

threads, unions, ' O ' rings are coated

with

cover

seam.

Remove the old sealing

refrigerant oil prior to fitting.

compound from the body and top cover.

the top of the cover.

screws adjacent to the low pressure pipe

Evaporator Matrix or Expansion Valve 6 to 10

moulding.

and then charge the air conditioning system as

32. At the side of the unit remove the two screws

previously described with Refrigerant 12.

adjacent to the air intake aperture.

33. Lift the top cover off whilst feeding the blower

RESISTOR BLOCK

motor wiring and air control flap rod through

their respective apertures, thus exposing the

Removal

blower

motor,

heater

matrix

and

air

conditioning evaporator matrix.

1.

Disconnect the battery.

Refitting

30. Remove the four screws and four nuts from

NOTE: Depending

upon

which unit has been

31.

From the front of the unit remove the

two

Heater Matrix or Blower Motor

3

to

5

refitted reverse the appropriate procedures:

2.

Detach the electrical connector from the.
resistor block.

3. Withdraw the relay module from it's socket.

socket, fuse holder and resistor block.

Blower motor unit removal only

34.

Remove the screws retaining the motor unit to

4. Remove the screws securing relay module

the casing.

35.

Release the three bracket retaining screws

5.

Move fuse holder and relay module socket

and withdraw motor and impeller.

aside and lift resistor block clear of the

36. Detach the star washer. spring clip and

evaporator.

impeller.

37. Remove the two nuts from the motor shroud

and lift clear.

Heater/Evaporator matrices removal only

38.

Lift the support plate and insulation pad from

the matrix.

three screws adjacent to the dump valve
outlet, in addition

to

the screws next to the

heater pipes.

40. Lift the evaporator and heater matrices

together with the supporting frame containing
the air direction flap clear

of

the casing.

41. Detach the evaporator matrix by releasing the

four screws, two at

both

ends of the support

bracket.

42. Detach the heater matrix

by

removing the

self-tapping screw.

39. From the bottom

of

the casing, remove the

Refitting

Expansion valve removal

6.

To

refit the resistor block, reverse the removal

43. Support the suction pipe union with suitable

procedure.

spanners and release.

44. Remove the bleed pipe retaining nut from the

suction pipe.

45. Remove the

spring clip

retaining the

expansion valve sensor pipe to the main
suction

pipe which

now

releases the

22

REISSUED: FEB 1993

ELECTRICAL EQUIPMENT

ELECTRICAL PRECAUTIONS

Battery disconnecting

The following guidelines are intended to ensure the

Before disconnecting the battery, switch

off

all

safety of the operator whilst preventing damage to

electrical equipment.

electrical

and any electronic components fitted to the

Battery charging

Before commencing any test procedure on a vehicle

ensure that the test equipment is working correctly

Recharge the battery out of the vehicle and keep the

and any harness or connectors are in good

top well ventilated. While being charged or

condition, this particularly applies to mains leads and

discharged, and for approximately fifteen minutes

plugs.

afterwards, batteries emit hydrogen gas which is
flammable. Always ensure any battery charging area

WARNING: Before commencing work on an

is well ventilated and that every precaution is taken

ignition system, all high tension terminals,

to avoid naked flames and sparks. See SECTION 10

adaptors and diagnostic equipment for testing

for battery maintenance.

should be inspected to ensure that they are

uately insulated and shielded to prevent

GENERAL PRECAUTIONS

ental personal contacts and minimize the

of shock. Wearers of surgically implanted

Switch-off ignition prior to making any connection or

maker devices should not be in close

disconnection in the system as electrical surge

proximity to ignition circuits or diagnostic

caused by disconnecting 'live' connections can

equipment.

damage electronic components.

Polarity

Never reverse connect the vehicle battery and

can cause tracking or high-resistance contacts.

always observe the correct polarity when connecting
test equipment.

High voltage circuits

Whenever disconnecting live high tension circuits
always use insulated pliers and never allow the open
end of a high tension lead to come into contact with
other components particularly electronic control units.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, since, high
voltage spikes can occur on these terminals.

Connectors and harness

Always ensure that these items are dry and oil free
before disconnecting and connecting test equipment.

Never force connectors apart either by using tools or
by pulling on the wiring harness. Always ensure
locking tabs are disengaged before removal and note
orientation to enable correct reconnection. Ensure

that any protective covers and substances are
replaced if disturbed. Having confirmed a component
to be faulty switch-off the ignition and disconnect the

battery. Remove the component and support the
disconnected

harness.

When

replacing

the

component keep oily hands away from electrical
connection areas and push connectors home until
any locking tabs fully engage.

Ensure hands and work surfaces are clean and free
of grease, swarf, etc. as grease collects dirt which

When handling printed circuit boards, treat them as
you would a hi-fi record

-

hold by the edges only.

Prior to commencing a test, and periodically during a

test, touch a good earth, for instance, a cigar lighter
socket, to discharge body static as some electronic
components are vulnerable to static electricity.

REISSUED: FEB 1993

1

vehicle.

ELECTRICAL EQUIPMENT

DISTRIBUTOR - 35DLM8

NOTE: Marking distributor enables refitting in

exact original position, but if engine is turned

The Lucas 35DLM8 distributor has

a

conventional

while distributor is removed, complete ignition

advance/retard unit

and

centrifugal automatic

timing procedure must be followed.

advance mechanism.

A

pick-up module, in conjunction with a rotating

7. Release the distributor clamp and remove the

timing reluctor inside the distributor body, generates
timing signals. These are applied to an electronic
ignition amplifier module mounted on the side of the

Refitting

distributor body.

NOTE: I f a new distributor is being fitted, mark

NOTE: The pick-up air gap is factory set.

Do

not

body in same relative position as distributor

adjust the gap unless the pick-up is being

removed.

changed or the base plate has been moved. Use

a

non-ferrous feeler gauge

to

set the air gap.

Remove and refit

Removing

distributor.

8. Leads for distributor cap should be connected

as illustrated.

Figures

1

to

8 inclusive indicate plug lead numbers.

RH

-

Right-hand side

of

engine, when viewed

1.

Disconnect battery.

from the rear.

2.

Disconnect vacuum pipe(s).

LH

-

Left-hand side

of

engine, when viewed

3.

Remove distributor cap.

from the rear.

4.

Disconnect low tension lead from coil.

5.

Mark distributor body in relation

to

centre line

of rotor arm.

9. If engine has not been turned whilst distributor

has been removed, proceed as follows (items

10 to 17).

10.

Fit new ' O ' ring seal to distributor housing.

11. Turn distributor drive until centre line of rotor

arm is 30° anti-clockwise from mark made on
top edge

of

distributor body.

12. Fit distributor in accordance with alignment

markings.

6.

Add alignment marks to distributor and front
cover.

NOTE: It may be necessary t o align oil pump
drive shaft t o enable distributor drive shaft t o
engage i n slot.

13. Fit clamp and bolt. Secure distributor in exact

orginal position.

14. Connect vacuum pipe to distributor and low

tension lead to coil.

15. Fit distributor cap.
16.

Reconnect battery.

17. Using suitable electronic equipment, set the

ignition timing,

See

IGNITION TIMING

ADJUSTMENT

2

REISSUED: FEB 1993

35

DLM8

Distributor components

1.

Cover

2.

HT

brush & spring

3.

Rotor arm

4. lnsul cover
5.

Pick-up module and base plate assembly

6.

Vacuum unit

7.

Amplifier module

8. O-ring oil seal
9.

Gasket