Content .. 132 133 134 135 ..

Defender 90 / 110 / 130. Manual - part 134

25.

Lift the evaporator clear of the vehicle and place

a bench with a suitable support underneath the

case t o ensure the heater pipes are not damaged.

26. Release the nuts and remove the bracket from

underneath the evaporator casing.

27.

Remove the wire clip and detach the dump valve

located underneath.

28. Release the seven self tapping screws securing the

outlet duct and carefully break the sealing

compound around the edge

of the duct and pull

ducting plate away from evaporator body.

29.

Remove the fifteen screws located around

t h e

cover seam, Remove the old sealing compound
from the body and

top cover.

30. Remove the four screws and four nuts from the top

of the cover.

31. From the front of the unit remove the two screws

adjacent to the low pressure pipe moulding.

32. At the side

of the

remove the two screws

adjacent to the air intake aperture.

33. Lift the top cover

off whilst feeding the blower

motor wiring and air control flap rod through their
respective apertures, thus exposing the blower

motor, heater matrix and air conditioning
evaporator matrix.

...

Blower motor unit removal only

Expansion valve removal

43. Support the suction pipe

union with suitable

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

the expansion valve and high pressure

pipe. Place valve

bench and unscrew the high

pressure pipe from the expansion valve.

46. Seal and cap all apertures; discard all ‘0’

rings

which are renewed

on assembly.

Refitting

47. Reverse procedures 46

11 noting that all threads,

unions,

rings are coated with

oil

prior to fitting.

NOTE: Depending upon which unit has been
refitted reverse the appropriate procedures:
Heater Matrix or Blower Motor 5

to 3

Evaporator Matrix

or Expansion Valve 10 to 6 and

then charge the air conditioning system as
previously described with Refrigerant 12.

RESISTOR

BLOCK

Removal

34. Remove the screws

the motor unit to

casing.

35. Release the three bracket retaining screws and

withdraw motor and impeller.

36. Detach

the star washer, spring clip and impeller.

37. Remove the two nuts from the motor shroud and

lift clear.

Stop the engine and secure the bonnet

in an open

2. Detach the blower motor wiring connector.
3. Remove the self tapping screw and lift the resistor

position.

block

out.

matrices removal only

38. Lift the support ptate and insulation pad from the

matrix.

39. From the bottom of the casing, remove the three

screws adjacent to the dump valve outlet,

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

the support bracket.

42.

Detach the heater matrix by removing

self-

tapping screw.

Refitting

Reverse procedures

3 to 1.

AIR

CONDITIONING

H. STEERING

EVAPORATOR BLOWER MOTOR

Steering

models

Rem

o v a

1. Open and secure the bonnet.

2. Release the plastic tie retaining the carburetter

breather pipe

the right hand air intake elbow.

Remove the pulsair pipe connected to the air

intake elbow.

Remove the right hand air intake elbow.

5 .

Disconnect the clip and blower motor wiring.

Release the blower motor cover fixings and

separate the casing slightly to allow the earth and
Lucar connectors to be released.

7. Remove the cover ensuring that a mark is made on

the casing to indicate the correct positioning

of the

blower motor when refitting.

Release the five self-tapping screws and withdraw
the blower motor and impeller. It may be necessary

to move the low pressure air conditioning pipe
aside to provide sufficient clearance.

9. Remove the centre nut

on the impeller and

carefully ease the impeller from the blower motor
shaft.

Refitting

Evaporator remove and refit

R.H. steering models

For removal

of the blower motor only, see section

“Evaporator Blower Motor”.

NOTE: It

is only required to evacuate the air

conditioning system when removing the evaporator

matrix or changing the expansion valve.

Rem

o v a

1. Place the vehicle in a ventilated area away from

2. Stop the engine and secure the bonnet

an open

3. Disconnect the battery.

Unscrew the radiator drain-plug and partially drain

5 .

Remove the air-cleaner.

6. Remove the caps from the compressor service

open flames and heat sources.

position.

the radiator.

valves.

Heater matrix only

Fully close (turn clockwise) the high pressure

8. Fully open (turn

the

pressure

9. Slowly disconnect the low prcssurc pipe from the

valve.

compressor rotor lock adaptor plate.

Remove the plastic

ring from the rotor lock

seal. Cap and seal both unions to prevent dirt or
moisture entering the system.

pipe to the upper engine bracket.

12. Remove the two plastic ties, securing the insulation

cover

the high pressure pipe and remove the

cover.

13. Whilst supporting both unions with suitable

1 1

10. Reverse procedures 9 to 1 ensuring that all seals

spanners,

unscrew

the

high

pressure

air

are replaced.

conditioning pipe from the evaporator.

IR CONDITIONING -

STEERING

Evaporator matrix and expansion valve only

14. Evacuate the air conditioning system as previously

described.

15.

Open (turn anti-clockwise)

the compressor service

valves and disconnect the gauge set. Cap

all pipes

and gauge connections to prevent dirt or moisture
entering the system.

16. Remove the insulating cover

on the low pressure

pipe.

17. Whilst supporting both unions with suitable

spanners,

unscrew

the

low

pressure

air

conditioning pipe from the evaporator.

18. Cap both ends to prevent dirt or moisture entering

the system.

19. Remove the two plastic ties, securing the insulation

cover on the high pressure pipe and remove the

cover.

20. Whilst supporting both unions with suitable

spanners,

unscrew

the

high

pressure

air

conditioning pipe from the evaporator.

Evaporator unit

21. Remove the self tapping screw securing the air

22. Disconnect the two ‘Ronco’ thermostat wires.
23. Disconnect the two heater hoses from

the side of

the evaporator unit.

24. Remove the vacuum pipe from the water valve

switch.

25. Remove the clip and cable connection from the

evaporator air flap rod. Use a new clip o n

bly.

control flap solenoid.

26. Disconnect the blower motor wiring connections.

27. Remove t h e screw retaining the blower motor

wiring tot he blower motor housing.

28. Remove the two bolts securing the blower motor

resistor block to the engine compartment.

29. Remove the bolt securing the front support

to the blower

motor

housing.

30. From

the vehicle rcmove the front passenger

carpet and five self tapping screws which retain the
toe-box cover.

31. Release the four bottom mounting bracket bolts,

ensuring that

the spacing washers from the two

innermost bolts are retrieved from the engine
bulkhead side.

32. From inside the engine compartment remove the

two 13

upper evaporator mounting bracket

bolts fitted to the engine bulkhead.

33. Lift the evaporator clear of the vehicle and place

a bench with the blower motor cover facing up.

34. Turn the evaporator unit around and remove

fixings retaining the blower motor housing duct.

35. Remove the “Ranco” thermostat from the top

the unit.

36. Remove the seven self-tapping screws securing

top and bottom

of the unit

37. Remove the

screws from the right hand side

of the unit.

38. Peel back t h e sponge pad on the outlet duct to

expose the last retaining screw. Remove the

39. Remove the two screws

on the top of the unit.

40. Remove the joint sealant around

seam and

separate the two halves of

evaporator cover

assembly

41. Remove the heater matrix from

evaporator

casing.

IR CONDITIONING -

R.H. STEERING

Evaporator matrix and Expansion valve only

42. Release the screws attached to the blower motor

retaining plate and remove the plate.

43. Remove the blower motor inner housing.
44. Remove the bleed-pipe retaining n u t from the

low

pressure pipe.

45. Remove the spring clip retaining the expansion

valve sensor pipe to the low pressure pipe and
remove the expansion valve and high pressure
pipe.

46. Unscrew the high pressure pipe from the expansion

valve.

47. Seal and cap all pipes and connections to prevent

dirt or moisture entering the system. Discard all

rings, which are renewed

refitting.

48. Release the two nuts adjacent to the dump valve.
49. Remove the two evaporator mounting screws from

each side

of the casing.

50. Release the two

evaporator mounting

bracket screws and pull the bracket away from the
evaporator.

51. Lift the evaporator matrix from the casing with

two

plates and place on a bench.

Refitting

52. Reverse procedures

51 to 21, ensuring that all

threads, unions and

‘0’ rings are coated with

refrigerant oil prior to fitting. Discard all old
rings and renew

on refitting. When reversing

procedure 31,

that the spacing washers are

fitted

the two innermost bolts.

NOTE: Depending upon which component has been
removed, reverse the appropriate procedure as
follows:
Evaporator matrix and expansion valve 20 to 2
Heater matrix 13 to 2.

Content .. 132 133 134 135 ..