Land Rover Defender V8i Workshop Supplement Rover Manual

							AIR CONDITIONING
1
ADJUSTMENT GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING: R134a is a hazardous liquid
and when handled incorrectly can cause
serious injury. Suitable protective clothing
must be worn when carrying out servicing
operations on the air conditioning system.
WARNING: R134a is odourless and
colourless. Do not handle or discharge in
an enclosed area, or in any area where the
vapour or liquid can come in contact with naked
flame or hot metal. R134a is not flammable, but
can form a highly toxic gas.
WARNING: Do not smoke or weld in areas
where R134a is in use. Inhalation of
concentrations of the vapour can cause
dizziness, disorientation. uncoordination,
narcosis, nausea or vomiting.
WARNING: Do not allow fluids other than
R134a or compressor lubricant to enter the
air conditioning system. Spontaneous
combustion may occur.
WARNING: R134a splashed on any part of
the body will cause immediate freezing of
that area. Also refrigerant cylinders and
replenishment trolleys when discharging will
freeze skin to them if contact is made.
WARNING: The refrigerant used in an air
conditioning system must be reclaimed in
accordance with the recommendations
given with a Refrigerant Recovery Recycling
Recharging Station.
NOTE: Suitable protective clothing
comprises: Wrap around safety glasses or
helmet, heatproof gloves, rubber apron or
waterproof overalls and rubber boots.REMEDIAL ACTIONS
1.If liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eyewash over the
eye to raise the temperature. If eyewash is not
available cool, clean water may be used. Cover
eye with clean pad and seek immediate medical
attention.
2.If liquid R134a is splashed on the skin run large
quantities of water over the area as soon as
possible to raise the temperature. Carry out the
same actions if skin comes into contact with
discharging cylinders. Wrap affected parts in
blankets or similar material and seek immediate
medical attention.
3.If suspected of being overcome by inhalation of
R134a vapour, seek fresh air. If unconscious,
remove to fresh air, apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its low evaporating
temperature of -30°C, -22°F R134a should
be handled with care.
WARNING: Do not allow a refrigerant
container to be heated by a direct flame or
to be placed near any heating appliance. A
refrigerant container must not be heated above
50°C, 122°F.
WARNING: Do not leave a container of
refrigerant without its cap fitted. Do not
transport a container of refrigerant that is
unrestrained, especially in the boot of a car. 
						

							82AIR CONDITIONING
2
ADJUSTMENT SERVICING PRECAUTIONS
Care must be taken when handling refrigeration
system components. Units must not be lifted by their
hoses, pipes or capillary lines. Hoses and lines must
not be subjected to any twist or stress. Ensure that
hoses are positioned in their correct run before fully
tightening the couplings, and ensure that all clips and
supports are used. Torque wrenches of the correct
type must be used when tightening refrigerant
connections to the stated value. An additional spanner
must be used to hold the union to prevent twisting of
the pipe.
Before connecting any hose or pipe ensure that
refrigerant oil is applied to the seat of the new 0 ring
but not to the threads.
Check the oil trap for the amount of oil lost.
All protective plugs on components must be left in
place until immediately prior to connection.
The receiver/drier contains dessicant which absorbs
moisture. It must be positively sealed at all times.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
Use alcohol and a clean cloth to clean dirty
connections. Ensure that all new parts fitted are
marked for use withR134a.
Refrigerant oil
Use the approved refrigerant lubricating oil - Nippon
Denso ND-OIL 8.
CAUTION: Do not use any other type of
refrigerant oil.
Refrigerant oil easily absorbs water and must not be
stored for long periods. Do not pour unused oil back
into the container.
When renewing system components, add the
following quantities of refrigerant oil:
Condenser 40ml, 1.4 fl oz............................................
Evaporator 80ml, 2.8 fl oz............................................
Pipe or hose 20ml, 0.7 fl oz..........................................
Receiver/drier 20ml, 0.7 fl oz........................................
Total refrigerant oil in system = 180ml, 6.3 fl ozA new compressor is sealed and pressurised with
Nitrogen gas. Slowly release the sealing cap, gas
pressure should be heard to release as the seal is
broken.
NOTE: A new compressor should always
have its sealing caps in place and these
must not be removed until immediately
prior to fitting.
Fitting a new compressor
A new compressor is supplied with an oil fill (X) of
180ml, 5.3 fl oz.
A calculated quantity of oil must be drained from a
new compressor before fitting.
To calculate the quantity of oil to be drained:
1.Remove sealing plugs from the OLD
compressor.
2.Invert compressor and gravity drain oil into
measuring cylinder. Rotating the compressor
clutch plate will assist complete draining.
3.Note the quantity of oil drained (Y).
4.Calculate the quantity (Q) of oil to be drained
from the NEW compressor using the following
formula:
X - (Y + 20ml, 0.7 fl oz) = Q
Rapid refrigerant discharge
When the air conditioning system is involved in
accident damage and the circuit is punctured, the
refrigerant is discharged rapidly. The rapid discharge
of refrigerant will also result in the loss of most of the
oil from the system. The compressor must be
removed and all the remaining oil in the compressor
drained and refilled as follows:
1.Gravity drain all the oil, assist by rotating the
clutch plate (not the pulley).
2.Refill the compressor with 130ml, 4.6 fl oz of
new refrigerant oil.
3.Plug the inlet and outlet ports.
Servicing Equipment
The following equipment is required for full servicing
of the air conditioning system.
Recovery, recycling and charging station
- Leak detector
- Thermometer +20°C to -60°C, 70°F to -70°F
- Safety goggles and gloves 
						

							AIR CONDITIONING
3
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
Service repair no - 82.30.20/01
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturers instructions.Recovery and recycling
1.Connect a Refrigerant Station to the high and
low pressure servicing connections.
2.Operate the refrigerant recovery system
according to the manufacturers instructions.
3.Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system. Recycling
should always be carried out with equipment
which is design certified by Underwriter
Laboratory Inc. for compliance with SAE-J1991.
Other equipment may not recycle refrigerant to
the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.
Evacuation and recharging
1.Add refrigerant oil to compressor if necessary.
2.Renew the receiver/drier.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system. 
						

							82AIR CONDITIONING
4
ADJUSTMENT 4.Operate the refrigerant evacuation system
according to the manufactures instructions.
NOTE: If the vacuum reading is below 700
mm Hg, 28 in Hg after 15 minutes, suspect
a leak in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes and then check the high
pressure lines.
CAUTION: The system must be Evacuated
immediately before recharging
commences. Delay between Evacuation
and Recharging is not permitted.
5.Operate the refrigerant recharging system
according to the manufacturers instructions.
Refrigerant to charge system = 900±30gm, 32
±1 oz.
6.If the full charge has not been accepted by the
system, start the engine and run it at 1500
rev/min for a minimum of 2 minutes.
Switch on the air conditioning system, open the
vehicle windows, set the temperature control to
cold and switch the blower to maximum speed.
7.Consult Refrigerant Station Manual for correct
procedure to complete the charge.
8.Carry out the air conditioning system
performance test.LEAK TEST SYSTEM
The following instructions refer to an electronic type
Refrigerant Leak Detector for use with R134a, which
is the safest and most sensitive.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using an inert gas (see below).
1.Place the vehicle in a well ventilated area but
free from draughts, as leakage from the system
could be dissipated without detection.
2.Follow the instructions issued by the
manufacturer of the particular leak detector
being used.
3.Commence searching for leaks by passing the
detector probe around all joints and components,
refrigerant gas is heavier than air.
4.Insert the probe into an air outlet of the
evaporator or into the evaporator drain tube.
Switch the air conditioning blower on and off at
intervals of ten seconds. Any leaking refrigerant
will be gathered in by the blower and detected.
5.Insert the probe between the magnetic clutch
and compressor to check the shaft seal for
leaks.
6.Check all service valve connections, valve plate,
head and base plate joints and back seal plate.
7.Check the condenser for leaks at the pipe
unions.
8.If any leaks are found, the system must be
discharged before rectification.
9.Rectify any leaks and recheck for leaks during
evacuation prior to charging.
Leak test using inert gas
Use Nitrogen or Helium gas.
1.Connect gas line to recharging station.
2.Pressurise system to 3 bar (45 lbf/in
2).
3.Carry out leak test as above. 
						

							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 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 and discard 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 fl.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; Refit
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 
						

							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; Refit
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