Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							AIR CONDITIONING
5
ADJUSTMENT AIR CONDITIONING SYSTEM - PERFORMANCE
TEST
WARNING: R134a is hazardousSee
Repair, General Precautions
.
Carry out this test with bonnet and doors or windows
open, air conditioning switched on, temperature
control set to cold and blower at maximum speed. Set
the air supply control to supply fresh air.
1.Close low pressure valve on refrigerant station.
2.Close high pressure valve on refrigerant station.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.4.Insert dry bulb thermometer into cold air outlet
and position dry and wet bulb thermometer close
to outside air inlet.
Do not spill water from the wet thermometer
(psychrometer).
5.Start engine and run it at 1500 rev/min for 10
minutes with air conditioning switched on.
6.Read both pressure gauges and thermometers.
Check readings against table below with
humidity between 60% and 80%.
7.Switch off air conditioning, stop engine,
disconnect test equipment.
Performance range
Intake temperature Outlet temperature Low pressure High pressure
68°F41-50°f 20 - 23 lbf/in
2116 - 190 lbf/in2
20°C5-10°C 1.4 - 1.6 bar 8.0 - 13 bar
75°F45-60°F 21 - 28 lbf/in
2130 - 200 lbf/in2
25°C7-15°C 1.5 - 2.0 bar 9.0 - 14 bar
85°F46-68°F 26 - 40 lbf/in
2190 - 230 lbf/in2
30°C8-20°C 1.8 - 2.8 bar 13 - 16 bar
95°F52-72°F 36 - 52 lbf/in
2230 - 270 lbf/in2
35°C11-22°C 2.5 - 3.5 bar 16 - 19 bar
Table 1
Ambient Compound Gauge High Pressure
Temperature Readings Gauge Readings
°C°F bar lbf/in
2bar lbf/in2
16 60 1,3-1,4 15-20 6,9-10,3 100-150
27 80 1,4-1,7 20-25 9,7-13,1 140-190
38 100 1,7-2,1 25-30 12,4-15,5 180-225
43 110 2,1-2,4 30-35 14,8-17,2 215-250 
						

							82AIR CONDITIONING
6
ADJUSTMENT SYSTEM TEST
1.Place the vehicle in a ventilated, shaded area
free from excessive draught, with the doors and
windows open.
2.Check that the surface of the condenser is not
restricted with dirt, leaves, flies, etc. Do not
neglect to check the surface between the
condenser and the radiator. Clean as necessary.
3.Switch on the ignition and the air conditioner air
flow control. Check that the blower is operating
efficiently at low, medium and high speeds.
Switch off the blower and the ignition.
4.Check that the evaporator condenserate drain
tube is open and clear.
5.Check the tension of the compressor driving belt,
and adjust if necessary.
6.Inspect all connections for the presence of
refrigerant oil. If oil is evident, check for leaks,
and repair as necessary.
NOTE: The compressor oil is soluble in
Refrigerant R134a and is deposited when
the refrigerant evaporates from a leak.7.Start the engine.
8.Set the temperature controls to cold and switch
the air conditioner blower control on and off
several times, checking that the magnetic clutch
on the compressor engages and releases each
time.
9.With the temperature control at maximum
cooling and the blower control at high speed,
warm up the engine and fast idle at 1000
rev/min.
10.Repeat at 1800 rev/min.
11.Gradually increase the engine speed to the high
range and check the sight glass at intervals.
12.Check for frosting on the service valves.
13.Check the high pressure hoses and connections
by hand for varying temperature. Low
temperature indicates a restriction or blockage at
that point.
14.Switch off the air conditioning blower and stop
the engine.
15.If the air conditioning equipment is still not
satisfactory, carry out a pressure test as
previously described in this section. 
						

							AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Disconnect battery negative lead.
2.Recover refrigerant from system.
See
Adjustment, refrigerant recovery recycling
recharging
3.Remove 2 bolts securing hose flanges to
compressor.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
4.Disconnect high pressure pipe from compressor.
5.Disconnect low pressure pipe from compressor.
6.Remove O ring from each flange.
7.Disconnect multiplug from compressor clutch
fly-lead
8.Release drive belt from compressor pulley.
See
ELECTRICAL, Repair, Auxiliary drive belt
9.Remove 4 bolts securing compressor to
mounting bracket.
10.Remove compressor from mounting bracket.
Refit
11.New compressor: Drain oil from new compressor
outlet port. Drain and measure oil equal to
amount drained from old compressor, add 30 ml,
1 oz extra to this amount and refill new
compressor through outlet port.
12.Locate compressor in mounting bracket, fit bolts
and tighten to
25 Nm, 18 lbf ft.
13.Connect multiplug to fly-lead.
14.Fit NEW O rings to each pipe flange, lubricate
with refrigerant oil.
15.Engage pipe flanges, fit bolts and tighten to
10
Nm, 7 lbf ft.
16.Fit compressor drive belt.See ELECTRICAL,
Repair, Auxiliary drive belt
17.Recharge refrigerant system.See Adjustment,
refrigerant recovery recycling recharging
18.Reconnect battery negative lead.
19.Leak test disturbed joints.
See Adjustment,
leak test system
20.Carry out system test.See Adjustment,
System test
CONDENSER FAN
Service repair no - 82.15.01
Remove
1.Remove grille panel.
See CHASSIS AND
BODY, Repair, grille panel
2.Disconnect multiplug from condenser fan
fly-lead.
3.Withdraw fly-lead from between radiator and
panel.
4.Remove nuts securing fan to condenser
brackets.
5.Remove fan assembly.
Refit
6.Position fan on brackets and secure with nuts.
7.Pass fly-lead through and connect to multiplug.
8.Fit grille panel.
See CHASSIS AND BODY,
Repair, grille panel 
						

							82AIR CONDITIONING
2
REPAIR CONDENSER
Service repair no - 82.15.07
Remove
1.Disconnect battery negative lead.
2.Recover refrigerant from system.
See
Adjustment, refrigerant recovery recycling
recharging
3.Remove condenser fan.See condenser fan
4.Remove 4 bolts securing cross-braces to top
panel and chassis brackets.
5.Remove 2 cross-braces.
6.Using a backing spanner, loosen union nut
securing inlet pipe to condenser and disconnect.
7.Using a backing spanner, loosen union nut
securing outlet pipe to condenser and
disconnect.
8.Remove and discard O ring from each union.
CAUTION: Plug the connections.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant.
9.Remove 4 screws securing lower brackets to
condenser.
10.Remove 4 bolts securing brackets to top panel.
11.Release pipes and remove condenser assembly.
Do not carry out further dismantling if
component is removed for access only.
12.Transfer brackets to new condenser.Refit
13.Fit NEW O rings to each union, lubricate with
refrigerant oil. New condenser, add 40 ml, 1 fl oz
refrigerant oil.
14.Add 40 ml, 1 fl oz of refrigerant oil to new
condenser.
15.Position condenser and engage pipes.
16.Secure brackets to top panel.
17.Secure lower brackets to condenser.
18.Using a backing spanner, tighten union nuts
securing pipes to condenser.
19.Fit condenser fan.
See condenser fan
20.Recharge refrigerant system.See Adjustment,
refrigerant recovery recycling recharging
21.Reconnect battery negative lead.
22.Leak test disturbed joints.
See Adjustment,
leak test system
23.Carry out system test.See Adjustment,
System test 
						

							AIR CONDITIONING
3
REPAIR RECEIVER DRIER
Service repair no - 82.17.01
Remove
CAUTION: If receiver drier is to be refitted,
the ports must be blanked off immediately
on disconnection. Exposed life of unit is
15 minutes.
1.Disconnect battery negative lead.
2.Recover refrigerant from system.
See
Adjustment, refrigerant recovery recycling
recharging
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant.
3.Clean area around receiver drier connections.
4.Disconnect multiplug from trinary switch.
5.Remove trinary switch from receiver drier.
CAUTION: Plug the connections.
6.Disconnect 2 pipe unions from receiver drier.
7.Remove and discard O rings from pipe flanges.
8.Fully loosen clip securing receiver drier to
bracket.
9.Remove receiver drier from clip.Refit
10.Fit NEW O ring to each pipe flange, lubricate
with refrigerant oil.
11.Add 20ml, 0.7 fl oz of refrigerant oil to NEW
receiver drier.
12.Position receiver drier in clip, tighten clip but do
not clamp.
13.Engage pipes and tighten unions to
6 Nm, 4.5
lbf ft
.
14.Fit trinary switch to receiver drier and tighten to
11Nm, 8 lbf ft.
15.Connect multiplug to trinary switch.
16.Tighten receiver drier clamp.
17.Evacuate and recharge air conditioning system.
See Adjustment, refrigerant recovery
recycling recharging
18.Perform a leak test on disturbed joints.
19.Carry out system test.
See Adjustment,
System test 
						

							82AIR CONDITIONING
4
REPAIR TRINARY PRESSURE SWITCH
Service repair no - 82.20.04
Remove
1.Disconnect battery negative lead.
2.Recover refrigerant from system.
See
Adjustment, refrigerant recovery, recycling,
recharging
3.Access below front RH of vehicle: Disconnect
multiplug from switch.
4.Remove switch from adaptor.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant.
5.Remove O ring from switch and discard.
Refit
6.Lubricate NEW O ring with refrigerant oil and fit
to switch.
7.Fit switch to adaptor and tighten to
11 Nm, 8 lbf
ft.
8.Connect multiplug.
9.Evacuate and recharge air conditioning system.
See Adjustment, Refrigerant recovery,
recycling, recharging
10.Reconnect battery negative lead.
11.Carry out system test.
See Adjustment,
System test
RELAY - FAN INTERLOCK
Service repair no - 82.20.08
Remove
1.Lever under each bottom corner and extract cold
air vents from bezel, 1 from LH side and 2 from
RH side.
2.Remove screw securing underside of bezel to
panel
3.Remove 3 screws securing inside of bezel to
panel 
						

							AIR CONDITIONING
5
REPAIR
4.Lift bezel away from evaporator casing
5.Withdraw capillary tube from evaporator fins.
6.Disconnect multiplug from fan interlock relay.
7.Remove securing screw and remove relay from
rear of bezel.
Refit
8.Fit screw and secure relay to rear of bezel.
9.Connect multiplug to fan interlock relay.
10.Position bezel assembly and insert capillary tube
60 mm, 2.5 in into evaporator fins.
11.Fit bezel assembly to panel and above
evaporator casing, secure with screws.
12.Fit cold air vents.
13.Carry out system test.
See Adjustment,
System test
RELAY - CONDENSER FAN
Service repair no - 82.20.09
Remove
1.Disconnect multiplug from relay.
NOTE: Connector wiring: B/S, N/P, N/S,
N/W
2.Release securing screw and remove relay from
side of evaporator casing.
Refit
3.Fit screw and secure relay to side of casing.
4.Connect multiplug to relay.
5.Carry out system test.
See Adjustment,
System test 
						

							82AIR CONDITIONING
6
REPAIR CONTROL SWITCHES
Service repair no - 82.20.10 - Temperature Control
Switch
Service repair no - 82.20.11 - Fan Switch
Remove
1.Remove fascia duct bezel.
See fascia duct
bezel
2.Pull control knobs from switches.
3.Remove switch panel.
4.Remove nut securing switch to bezel.
5.Remove switch.
NOTE: Fan switch to left.
Refit
6.Fit temperature control switch. Position capillary
tube inside duct to RH side.
7.Fit and tighten nut securing switch to bezel.
8.Fit switch panel.
9.Fit control knobs.
10.Fit fascia duct bezel.
See fascia duct bezel;
Refit
11.Carry out system test.See Adjustment,
System test
RESISTOR UNIT
Service repair no - 82.20.26
Remove
NOTE: Access below evaporator unit.
1.Loosen outer screw securing resistor unit to
clamp.
2.Rotate resistor on motor.
3.Disconnect Lucars from resistor unit.
NOTE: Resistor wires: G, U, R and O
4.Remove screws securing resistor to clamp.
5.Remove resistor unit and clamp.
Refit
6.Position clamp over motor and place resistor,
terminals downward, onto motor.
7.Fit screws and tighten inner screw only.
8.Fit Lucars to resistor unit, in correct sequence.
9.Rotate resistor to fitted position and tighten outer
screw.
10.Carry out system test.
See Adjustment,
System test 
						

							AIR CONDITIONING
7
REPAIR RELAY - EVAPORATOR BLOWER
Service repair no - 82.20.27
Remove
1.Disconnect multiplug from relay.
NOTE: Connector wiring: B, G, N, S/P
2.Release securing screw and remove relay from
side of evaporator casing.
Refit
3.Fit screw and secure relay to side of casing.
4.Connect multiplug to relay.
5.Carry out system test.
See Adjustment,
System test
RELAY - COMPRESSOR
Service repair no - 82.20.51
Remove
1.Disconnect multiplug from relay.
NOTE: Connector wiring: G, B/W, N/R, N/W
2.Release securing screw and remove relay from
side of evaporator casing.
Refit
3.Fit screw and securing relay to side of casing.
4.Connect multiplug to relay.
5.Carry out system test.
See Adjustment,
System test
FASCIA DUCT BEZEL
Service repair no - 82.20.79
Remove
1.Lever under each bottom corner and remove
cold air vents from bezel.
2.Remove screw securing underside of bezel to
panel.
3.Remove 3 screws securing inside of bezel to
panel.
4.Lift bezel away from evaporator casing.
5.Withdraw capillary tube from evaporator fins.
6.Disconnect multiplug from fan interlock relay.
7.Remove 2 screws securing cover to rear of
bezel. 
						

							82AIR CONDITIONING
8
REPAIR
8.Disconnect 2 Lucars from temperature control
switch.
9.Disconnect multiplug from fan switch.
10.Remove bezel assembly.
Do not carry out further dismantling if component
is removed for access only.
11.Pull control knobs from switches.
12.Remove switch panel.
13.Remove nuts securing switches to bezel.
14.Remove temperature control switch.
15.Remove fan switch.
16.Transfer components to new panel.Refit
17.Position bezel assembly and connect multiplug
to fan switch.
18.Connect Lucars to temperature control switch.
19.Position capillary tube to RH side of bezel.
20.Fit screws securing cover to rear of bezel.
21.Connect multiplug to fan interlock relay.
22.Position bezel assembly and insert capillary tube
60 mm, 2.5 in into evaporator fins
23.Fit bezel assembly to panel and above
evaporator casing, secure with screws.
24.Fit cold air vents.
25.Carry out system test.
See Adjustment,
System test