Defender 300Tdi (1996+). Manual — part 97
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AIR CONDITIONING
11
REPAIR
9. Remove screw securing blower motor mounting
bracket to side of casing.
10. Remove nut and washer securing blower motor
housing to pedestal mounting bracket.
11. Lift blower motor assembly from casing.
12. Remove 3 screws and withdraw blower motor
and impellor from housing. Note position of side
mounting bracket and spacing washers between
motor mounting and housing.
13. Remove star washer and withdraw impeller from
blower motor.
14. Lift motor from plastic mounting.
15. Slacken retaining clip and remove 3 support
brackets.
Refit
16. Secure support brackets to new blower motor.
Do not fully tighten clip at this stage.
17. Insert motor into plastic mounting and fit
impeller.
18. Locate spacing washers, side mounting bracket,
and fit motor and mounting into motor housing.
19. Secure assembly to motor housing and fully
tighten support bracket retaining clip.
20. Fit blower motor assembly in main casing.
21. Apply sealing compound around top edge of
main casing.
22. Feed blower motor wiring through top cover and
fit grommet.
23. Fit top cover to casing. Ensure thermostat
temperature probe is inserted in top of
evaporator. Apply mastic sealant to air flap
operating rod aperture.
24. Apply sealing compound to joint face of blower
motor outlet duct.
25. Locate duct over blower motor outlet and secure
to casing.
26. Fit heater/cooler unit
See Heater/cooler unit.
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82
AIR CONDITIONING
12
REPAIR
BLOWER MOTOR ASSEMBLY - RH DRIVE
Service repair no - 82.25.14
Remove
1. Disconnect blower motor wiring plugs.
2. Remove 2 screws securing blower motor cover
to main casing.
3. Withdraw cover sufficiently to release motor
Lucar connector and earth eylet. Remove cover.
4. Remove 6 screws and withdraw blower motor
and impeller.
5. Remove retaining nut and washer and withdraw
impeller from blower motor shaft.
Refit
6. Secure impeller on new blower motor.
7. Fit blower motor assembly in main casing.
8. Fit Lucar connector and earth eyelet to blower
motor.
9. Fit blower motor cover and connect wiring plugs.
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AIR CONDITIONING
13
REPAIR
HEATER/COOLER UNIT - RH DRIVE
Service repair no - 82.25.21
Remove
1. Disconnect battery.
2. Recover refrigerant from air conditioning system
See Refrigerant recovery, recycling,
recharging.
3. Release ties, remove insulation cover and
disconnect evaporator low pressure pipe.
4. Disconnect evaporator high pressure pipe.
5. Discard all pipe connection ’O’ rings. Cap or plug
all connections to prevent ingress of dirt and
moisture.
6. Using suitable pipe clamps, clamp heater matrix
feed and return pipes at heater/cooler unit.
7. Remove screw securing air control flap solenoid.
8. Disconnect 2 leads from thermostat.
9. Remove pipe from water valve vacuum switch.
10. Remove retaining clip and disconnect control
cable from evaporator flap operating rod.
11. Remove screw and release outer cable retaining
bracket.
12. Disconnect blower motor wiring plugs and
release harness retaining clip from housing.
13. Remove bolt securing front support bracket to
blower motor housing. If necessary, remove
blower motor resistor block to facilitate
operation.
14. From inside vehicle remove front passenger
carpet, if fitted.
15. Remove fixing screws and fold back footwell
insulation.
16. Remove 4 bolts securing heater/cooler unit lower
mounting bracket to bulkhead. Ensure spacing
washers from two innermost bolts are retrieved
from engine bulkhead side.
17. From inside engine compartment remove 2 bolts
securing top heater/cooler unit mounting bracket
to engine bullkhead.
18. Lift heater/cooler unit clear of air duct seal and
remove from vehicle.
82
AIR CONDITIONING
14
REPAIR
Refit
19. Coat unions, threads and new ’O’ rings with
refrigerant oil prior to reassembly.
20. Position heater/cooler unit in engine
compartment and locate with air duct seal.
21. Secure unit top and bottom mounting brackets to
bulkhead and support bracket to front of unit
casing. Fully tighten fixing bolts when unit is
correctly positioned.
22. If applicable, fit blower motor resistor block to
vehicle wing.
23. Connect blower motor wiring plugs.
24. Fit footwell insulation and carpet.
25. Fit control cable to evaporator flap operating rod
using new clip. Secure outer cable.
26. Connect water valve vacuum switch pipe and
thermostat leads.
27. Fit air control flap solenoid to side of
heater/cooler unit.
28. Reconnect heater matrix hoses.
29. Connect high pressure pipe to evaporator.
30. Connect low pressure pipe and fit insulation
cover.
31. Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
32. Reconnect battery.
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