Land Rover Defender 90 110 Workshop Book 5 Rover
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AIR CONDITIONING-L.H. R.H. STEERING 182 2k . - NOTE: A special wrench should be used to adjust the d.:, ~ . valve to prevent damage to the stem. The stem type service valve has three positions, the operation of which is explained as follows. A. ON: FULLY ANTICLOCKWISE - Normal operating position, and the position which is used for connecting and disconnecting the manifold gauge set, is the on position. The stem is turned fully anticlockwise. This seals the service gauge port from receiving any refrigerant flow. - - B. MID (Test) POSITION - After the service gauge manifold has been installed (the valve stem is in the on position), turn the valve stem the required number of turns clockwise. This will put the valve stem seat midway in thc service valve and allow full system operation while permitting refrigerant pressure to reach the gauges. C. OFF: FULLY CLOCKWISE - With the service valve stem turned fully clockwise, the valve will block passage of refrigerant flow through the system. As illustrated, the refrigerant flow to or from the compressor (depending on whether it is high side or low side) is blocked. ST1386M WARNING: NEVER operate the air conditioning system with the service valves in the OFF POSITION, it will cause severe damage to the compressor. 3
AIR CONDITIONING - L.H. & R.H. STEERING Schrader Type These are secured to the head of the compressor, and the suction and discharge flexible end connections are secured to them by unions. The service valves are identified as suction or low pressure, and discharge or high pressure. Whilst they are identical in operation they are not interchangeable, as the connections are of different sizes. The valve with the larger connections fits the suction side. As the name suggests, these valves are for service purposes, providing connections to external pressure/ vacuum gauges for test purposes. In combination with charging and testing equipment they are used to charge the system with refrigerant. T Schrader service valve B. OFF: FULLY CLOCKWISE - With the service valve stem turned fully clockwise, the valve will block passage of refrigerant flow through the system. As illustrated, the refrigerant flow to or from the compressor (depending on whether it is high side or low side) is blocked. WARNING: NEVER operate the air conditioning system with the service valves in the OFF POSITION, it will cause severe damage to the compressor. Valve Core Remover Where Schrader Valve depressors are not fittcd to the Testing equipment lines Valve core removers can be used. Valve Core Removal The use of valve core removers will facilitate servicing operations and should be used as follows: 1. Close all valves on the charging trollcy. 2. Remove the service valve cap and seals from the valve core remover. 3. Withdraw the plungcr as far as possible and connect the core remover to the service valve. 4. Connect the hose to the core remover. 5. Dcpress the plunger until it contacts the valve core. Unscrew the valve until it is free. Withdraw the plunger to its full extent. Service valve caps must be replaced when service operations are completed. Failure to replace caps could ST1496M 5 rcsult in refrigerant loss and system failure. 1. Valve stem 2. Hose connection 3. Service valve 4. Schrader valve core 5. Compressor port 5 9 3 NOTE: A special wrench should be used to adjust the valve to prevent damage to the stem. ST1497M The Schrader type service valve has two positions, the operation of which is explained as follows. A. ON: FULLY ANTICLOCKWISE - Normal operating position, and the position which is used for connecting and disconnecting the manifold gauge set, is the on position. The stem is turned fully anticlockwise. rlhis seals the service gauge port from receiving an, refrigerant flow. 4
AIR CONDITIONING- L.H. & R.H. STEERING ELECTRICAL CIRCUIT DIAGRAM Key to Circuit Diagram 1. 2 3. 4. 5. 6. 7. 8. 9 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Thermostat Condenser fan relay 5 amp fuse 17 amp fuse Compressor clutch relay L.H. fan R.H. fan High pressure switch Compressor clutch temperature switch Compressor clutch Fan temperature switch Blower fan relay Diode -Diesel engines only Termination point* Ignition feed pick -off point Starter solenoid pick -off point 30 amp fuse 30 amp fuse Fan speed selector switch Wiring U = 1st speed R = 2ndspeed 0 = 3rdspeed Y = 4thspeed NOTE: R.H. steering models have only three fan speeds ielay 9ir conditioning on/off switch 22. Evaporator motor 23. Resistor block * denotes: L.H. petrol, L.H.1R.H. diesel models, termination at starter solcnoid. R.H. petrol models, termination via link lead to ignition switch. Key to cable colours B Black G Green K Pink L tight N Brown 0 Orange P Purple R Red S Slate U Blue W White Y Yellow The last letter of a colour code denotes the tracer colour 5
82 I AIR CONDITIONING - L.H. & R.H. STEERING VOLTAGE AT BOTH ENDS OF FUSE CHECK FOR STALLED MOTOR f f + t MOTOR OK MOTOR STALLED * CHECK MOTOR GROUND CHECK FOR SHORT REPLACE MOTOR CIRCUIT AND CORRECT ELECTRICAL AIR CONDITIONER BLOWER MOTOR AND CONTROL SYSTEM DIAGNOSIS VOLTAGE AT BATTERY SIDE ONLY * REPLACE FUSE BLOWER MOTOR OPERATES 1 INSPECT RESISTOR BLOCK 1 RESISTOR BLOCK RESISTOR BLOCK OK INSPECT BLOWER RESISTOR BLOCK I REPLACE SWITCH IF DEFECTIVE I BLOWER MOTOR INOPERATIVE I INSPECT FUSE I c 1 CHECK FOR BATTERY 1 BETWEEN MOTOR GROUND +- MOTOR RUNS LOCATE OPEN CIRCUIT I I ATTACH JUMPER WIRE FROM MOTOR FEED WIRE TO BATTERY POSITIVE POST MOTOR DOES NOT RUN f f + MOTOR RUNS REPLACE MOTOR CHECK VOLTAGE AT RESISTOR CONNECTION AT ALL SWITCH POSITIONS CHECK RESISTOR CONTINUITY AND CONNECTIONS 1 I I I 1 VOLTAGE AT ALL SWITCH POSITIONS -~ ~ + I 1 I REPLACE RESISTOR I NO VOLTAGE IN ONE OR MORE SWITCH POSITIONS REMOVE CONNECTOR FROM SWITCH AND CHECK FOR VOLTAGE AT BATTERY TEKMINAL VOLTAGE AT BAITERY TERMINAL TERMINAL f f LOCATE OPEN CONNECTION REPLACE SWITCH AND CORRECT 6
AIR CONDITIONING - L.H. & R.H. STEERING 1821 Type of Evaporator Weather Air Temp F (C) . .* a-.~ I. >-
1821 AIR CONDITIONING - L.H. & R.H. STEERING FAULT A. HIGHHEAD PRESSURE B. LOWHEAD PRESSURE C. HIGH SUCTION PRESSURE 5. LOW SUCTION E. NOISY EXPANSION VALVE (steady hissing) F. INSUFFICTENT COOLING G. COMPRESSOR BELT H. ENGINE NOISE ANDiOR VIBRATION CAUSE 1. Overcharge of refrigerant. 2. Air in system. 3. 4. Condenser fan motor defective. Condenser air passage clogged with dirt or other foreign matter. I. 2. 3. Defective compressor Undercharge of refrigerant; evident by bubbles in sight glass while system is operating. Split compressor gasket or leaking valves 1. Slack compressor belt. 2. Refrigerant flooding through evaporator into suction line; evident by ice on suction line and suction service valve. Compressor suction valve strainer restricted. Leaking compressor valves, valve gaskets and/or service valves. Rcceiveddrier stopped; evident by temperature difference between input and output lines. 3. Expansion valve stuck open. 4. 5. 6. 1. Expansion valve thcrmobulb not operating. 2. Expansion valve sticking closed 3. Moisture freezing in expansion vaivc orifice. Valve outlet tube will frost while inlet hose tube will have littlc or no frost. System operates Dust, paper scraps, or other debris restricting evaporator blower grille. Dcfcctivc evaporator blower motor, wiring, or blower switch. 1. 5. I. Low refrigerant charge; evident by bubbles in sight glass. I. !. I. Compressor not pumping. Expansion valve not operating properly. Low refrigerant charge; evident by bubbles in sight glass. !. Belt tension !. Excessive head pressure. !. Incorrect alignment of pulleys or worn belt not riding properly. 1. Nicked or broken pulley. i. Frozen compressor. . !. i. i. Rough idler pulley bearing. ;. 1. _ I. Excessive head pressure. 1. Incorrect compressor ail. Loose or missing mounting bolts. Broken mounting bracket, idler bracket, or brace. Loose llywheel or clutch retaining boit. Bent, loose, or improperly mounted engine drive Incorrect installation of clutch bearing seal. Insecure mountings of accessories: gcncrator, power steering, air filter, etc. pulley. REMEDY 1. Purge with bleed hose until bubbles start to appear in sight glass; then, add sufficient refrigerant gas to clear sight glass. Slowly blow charge to atmosphere. Install new drier; evacuate and charge system. 2. 3. Clean condenser of debris. 4. Replace motor. 1. 2. 3. Replace compressor. Evacuate and recharge the system. Check for leakage. Replace gasket and install new drier, evacuate, and charge the system. 1. Adjust belt tension. 2. Check thermobulb. Bulb should be securely clamped to clean horizontal section of copper suction pipe. 3. Replace expansion valve. 1. Replace compressor. 5. 5. Replace valves and/or gaskets. Install new drier, evacuate, and charge the system. Install new drier, evacuate and charge the system. I Warm thcrmobulb with hand Suction should rise rapidly to 20 Ibs. or more. If not, replace expansion-valve. Check inlet side screen. Clean if clogged. Refer to C-2 and C-3. ?. 3. Install new drier, evacuate and charge the system. periodically. Refer to Fault Diagnosis for Elcctrical System. i. Clean grilles as required. j. . Leak test. Repair or replace components as required. . !. i. Refer to C-2, C-3, D-2. D-3 and E. Refer to B-1 and E. Refer to B -2 and 8-3 . With tension gauge adjust to 100 Ibs. (45 kg); or tighten until depression of about A inch (1,25 cm) occurs across longest span. Refer to A-1 through A-4 and C-6. !. 1. Repair as needed. ._ Replace pulley. 8. Replace comprcssor. ~____~~ . Repair as necessary. .. Replace defective part. . Repair as necessary. . Replace bearing. . Repair as necessary. #, Replace bearing. . Repair as necessary . . Refer to A-I, A-2, A-3, A-4 and C-6. Refer to Compressor Oil Level Check. 8
AIR CONDITION NG - L.H. & R.H. STEERING (821 COMPRESSOR AND CLUTCH DIAGNOSIS COMPRESSOR CLUTCH WILL NOT ENGAGE 1 NO VOLTAGE AT CLUTCH I . OPEN FUSE PUSH-BUITTON SWITCH DEFECTIVE I FAULTY WIRING POOR CLUTCH GROUND v CYCLING CLUTCH SWITCH J I IF CONTACT OPEN REPLACE SWITCH I I t I VOLTAGE AT CLUTCH LOW + I OPEN CLUTCH-COIL~ 7 REPLACE COIL COMPRESSOR WILL NOT TURN PROPERLY CLUTCH ENGAGES BUT SLIPS OR SMOKES I I I t CLUTCH-SLIPPING c I I LOW VOLTAGE AT CLUTCH 1 CLUTCH COIL PARTIALLY SHORTED , c -4 I SEIZEDCOMPRESSOR 1 I BELTS SLIPPING I II r t id REPLACE COMPRESSOR AND ADJUST BELT TO PROPER I CLUTCHASSEMBLY I I TENSION L It I I REPLACE CLUTCH COIL 9
1821 AIR CONDTTIONING - L.H. & R.H. STEERING MECHANICAL AIR CONDITIONER BLOWER MOTOR AND CONTROL SYSTEM DIAGNOSIS t ENGTNE RUNNING TO *I PROVIDE VACUUM I -1 MODE CONTROL LEVER IN FLOOR DUMP POSTTION LOWER MOTOR OPERATIV i I f MODE CONTROL LEVER IN DE-MIST POSITION MODE CONTROL LEVER IN FASCIA OUTLET POSITION AIR DISCHARGE AT FASCIA I I I 1 .c NO AIR FROM FASCIA LOUVRES FAULTY MODE DOOR VACUUM SWITCH + FAULTY MODE DOOR NO DISCHARGE AIR FROM DE-MIST OUTLETS c NO AIR DISCHARGE FROM FLOOR DUMPS I I FAULTY BLOWER WHEEL I c FAULTY MODE DOOR ACTUATOR DOOR OPERATING LINK DISCONNECTED AT CONTROL LEVER OR FLOOR DUMP DOOR I I I BLOWER MOTOR AND INSUFFICIENT HEATING HOT WATER VALVE PASSENGERCOMPARTMENT AIR 1 CONTROL OPERATIVE 11 I I I * TEMPERATURE CONTROL INSUFFICIENT COOLING INOPERATIVE HOT WATER VALVE VACUUM SWTTCH MIS -ADJUSTED I I c I I I 1 I HOT WATER VALVE VACUUM SWITCH MIS-ADJUSTED BLEND AIR DOOR BOWDEN CABLE DISCONNECTED AT CONTROL LEVER OR AT DOOR CRANK HOT WATER VALVE STUCK IN CLOSED POSITION VACUUM LINE PINCHED I HOT WATER VALVE STUCK IN OPEN POSTTTON CLAMP SLIPPING VACUUM LINE PINCHED OR DISCONNECTED FROM ACTUATOR OR SWITCH BLEND ATR DOOR MIS-ADJUSTED 10
AIR CONDITIONING - L.H. & R.H. STEERING 1821 e L. .z CHARGING AND TESTING EQUIPMENT Connecting the gauge set NOTE 1: There are two methods of connecting the charging and testing equipment, depending on the operation to be carried out. The method described for ‘evacuating or charging with liquid refrigerant’ also applies to ‘pressure test’ and ‘compressor oil level check’ operations. .: :. NOTE 2: Various types of charge and test equipment are available depending upon the manufacturer chosen by the user. The equipment illustrated may differ slightly in layout to that possessed by the user, however, it is recommended that the user adheres to the appropriate manufacturer’s instructions for the charge and test equipment used in their workshop. % -NOTE: The boxed instructions in the following procedure refer to compressors with STEM type valves. All other instructions refer to SCHRADER type valves. Fitting 1. Ensure that all the valves on the charging and testing equipment are closed. Control valves on the particular equipment selected are numbered 1 to 4 as illustrated. The sequence may vary on other proprietary equipment. 2. Mount a 11,3 kg (25 Ib) drum of refrigerant upside down on the support at the rear of the charging equipment, and secure with the strap. ST 1393M 6. Place the vehicle in a ventilated area away from open flames and heat sources. Stop the engine, open and secure the bonnet. 7. Check that both service valves are fully opcn (turned anti -clockwise). 8. Put on the safety goggles. 9. Remove the caps from the gauge connections on the service ports. 10. Coat the threads and flares with refrigerant oil. 11. Connect the low pressure charging line (blue) from valve No. 1 to the comprcssor suction service port. 12. Connect the high pressure charging linc (rcd) from valve No. 2 to the compressor discharge scrvicc port. 13. Using the service wrench, turn the suction service valve stem ‘clockwise’ counting the number of turns necessary to close the valve. 1 ST 1392M ST 1412 M ‘ 3. Connect the hose from the bottom of the charging cylinder to the refrigerant drum valve. 4. Connect the hose between the bottom of the ‘2 c charging cylinder and the refrigerant control valve 5. Connect the hose between the vacuum pump valve 14. After the valve is fully closed, turn the stem out (anti -clockwise) half the number of turns counted, this should position the valve seat in i the mid (test) position. 11 (No. 4). and the vacuum control valve (No. 3).
182 I AIR CONDITIONING - L.H. & R.H. STEERING WARNING: Open connections slowly, keeping the 15. Turn the stem on the discharge valve clockwise until the pressure rises on the discharge pressure gauge. If the system is to be evacuated, the discharge service valve seat 16. The charging and testing equipment is now connected and ready for proceeding with the required operation. 16. Close the compressor discharge service port (turn anti -clockwise). --. Removing 17. If the engine has been operated, it must be stopped prior to disconnecting the charging and testing eq U i pm en t . 18. Close both service ports (turn fully anti-clockwise) until fully closed. 19. Close all valves on the charging and testing equipment. 20. Disconnect the charging lines from the service ports. 21. Refit the blanking caps to the compressor valve stems and service ports, and to the charging lines. 22. Close the bonnet. AIR CONDITIONING SYSTEM OPERATIONS Depressurising NOTE: The air conditioning refrigeration system contains ‘Refrigerant 12’ under pressure, and before any component is disconnected or removed, the system must be discharged of all pressure. Refrigerant 12 evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts. Extreme care must be taken to prevent any liquid refrigerant from contacting the skin and especially the eyes. Should any liquid refrigerant get into the eyes, use a few drops of sterile mineral oil to wash them out and then wash the eyes with a weak solution of boric acid. Seek medical attention immediatcly even though the initial irritation has ceased aftcr first aid treatment. Always wear safety goggles whea epeaing refrigerant cnnnections. 1. Place the vehicle in a ventilated area away from 2. Stop the engine. 3. Open and secure the bonnet. 4. Remove the caps from thc compressor service 5. Check that both compressor service valves are fully 6. Close all valves on the charging and testing 7. Put on safety goggles. 8. Connect the high pressure charging line (red) from valve No. 2 to the compressor discharge service port. 9. Run the (blue) hose to an open tapped container of approximately one litre capacity. Attach the hose to the container so that it will not blow out of the container. The purpose of the container is to collect any oil carried by the refrigerant. open flames and heat sources. ports. opened (turned anti -clockwise). equipment. *p-3. 6,,,- 10. Open the compressor discharge service port a quarter of a turn. 11. Open valve No. 2 fully. 12. Slowly open the valve No. 1 one turn to allow the refrigerant to escape, if necessary, adjust the refrigerant flow so that the oil captured in thc container is not blown out of the container. 12 11 ST 1413M 13. Measure the amount of oil discharged from the system so that an equal amount of new oil can bc returned to the system during the charging operation. Discard the old oil. 14. When the gauge pressure is below 50 psi, slowly open the valve No. 1 to maintain refrigerant flow. 15. When the pressure has been reduced, and the system has been completely discharged, close the valves Nos. 1 and 2 on the charging and testing equipment.