Land Rover Defender V8i Workshop Supplement Rover Manual

							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
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 
						

							AIR CONDITIONING
5
REPAIR 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
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
6
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 
						

							AIR CONDITIONING
7
REPAIR EXPANSION VALVE
Service repair no - 82.25.01
Remove
1.Remove evaporator.
See evaporator
2.Using a backing spanner, loosen union nut and
remove high pressure pipe.
3.Discard O ring.
4.Pull insulation away from capillary tube coil and
low pressure pipe.
5.Loosen clip and withdraw capillary tube coil from
low pressure pipe.
6.Loosen capillary tube union and disconnect
union from low pressure pipe. Discard O ring.
7.Using a backing spanner, loosen union nut and
remove expansion valve from pipe. Discard O
ring.
Refit
8.Lubricate NEW O rings with refrigerant oil and
fit to pipe ends.
9.Fit expansion valve to pipe, DO NOT tighten
union nut.
10.Connect capillary tube and tighten union nut.
11.Position capillary tube coil on low pressure pipe
and secure with clip.
12.Wrap capillary coil and union with Prestite tape.
13.Connect high pressure pipe to expansion valve,
carefully align with low pressure pipe and tighten
union nut.
14.Tighten expansion valve union nut.
15.Fit evaporator.
See evaporator; Refit
16.Carry out system test.See Adjustment,
System test
BLOWER MOTOR ASSEMBLY
Service repair no - 82.25.14
Remove
1.Remove evaporator.
See evaporator
2.Move passenger seat fully rearward.
3.Position evaporator unit above centre console
and seat panel.
4.Disconnect Lucars (B and O wires) from blower
motor.
5.Remove screws securing blower units to casing.
6.Release blower unit flanges from casing, sealed
with sealant.
7.Disconnect Lucars from resistor unit.
NOTE: Wire positions: G, U and R wires.
8.Remove blower motor unit.
Do not carry out further dismantling if component
is removed for access only.
9.Remove screws securing resistor unit to blower
motor. Note alignment of resistor unit.
10.Remove resistor unit and bracket.
11.Fit resistor unit to blower motor. 
						

							82AIR CONDITIONING
8
REPAIR Refit
12.Clean sealant from blower flanges.
13.Apply a bead of Silicone Sealant around each
blower flange.
14.Connect Lucars to resistor unit in correct order.
15.Position blower flanges on evaporator casing
and secure with screws.
16.Connect Lucars (B and O wires) to blower motor.
17.Fit evaporator.
See evaporato; Refit
18.Carry out system test.See Adjustment,
System test
EVAPORATOR
Service repair no - 82.25.20
Remove
1.Disconnect battery negative lead.
2.Recovery refrigerant from air conditioning
system.
See Adjustment, Refrigerant
recovery recycling recharging
3.Remove fascia duct bezel.See fascia duct
bezel
4.Remove 3 nuts securing evaporator casing to
mounting bracket.
5.Disconnect drain tube from drain pipe on LH side
of casing.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant.
6.Position 2 heater hoses to side of air intake tube.
7.Using a backing spanner, loosen union nut from
evaporator return pipe and disconnect. Discard
O ring. 
						

							AIR CONDITIONING
9
REPAIR 8.Using a backing spanner, loosen union nut from
evaporator feed pipe and disconnect. Discard O
ring.
CAUTION: Plug the connections.
9.Ease 2 evaporator studs from their rubber
bushes, release grommet from bulkhead,
withdraw pipes from aperture and position
evaporator unit on floor.
10.Remove screw securing harness P clip to rear
of casing.
11.Disconnect Lucar (B wire) from motor.
12.Disconnect Lucars (G, U, and R wires) from
resistor unit.
13.Remove screw securing mounting bracket flange
to casing.
14.Remove screws securing each end of blower
flanges to upper casing.
15.Remove 6 screws securing upper to lower
casing.
16.Remove tape sealing air duct inside casing.
17.Release tape sealing pipes to casing.
18.Cut through sealant along casing joint and
gaskets.
19.Ease upper from lower casing and remove upper
casing.
20.Lift evaporator unit from lower casing.
Do not
carry out further dismantling if component is
removed for access only.
21.Using a backing spanner, loosen union nut from
pipe and remove high pressure pipe. Discard O
ring.
22.Loosen clip and withdraw capillary tube coil from
low pressure pipe and withdraw coil from pipe.
23.Loosen capillary tube union nut and disconnect
from low pressure pipe. Discard O ring.
24.Using a backing spanner, loosen union nut and
remove expansion valve from pipe. Discard O
ring. 
						

							82AIR CONDITIONING
10
REPAIR Refit
25.Lubricate NEW O rings with refrigerant oil and
fit to pipe ends.
26.Fit expansion valve to pipe, DO NOT tighten
union nut.
27.Connect capillary tube and tighten union nut.
28.Position capillary tube coil on low pressure pipe
and secure with clip.
29.Wrap capillary coil and union with Prestite tape.
30.Connect high pressure pipe to expansion valve,
carefully align with low pressure pipe and tighten
union nut.
31.Tighten expansion valve union nut.
32.Position evaporator unit in lower casing, align
bracket and engage blower flange screws, DO
NOT tighten.
33.Position upper casing, engage lower casing
flange and secure with screws. Ensure mounting
bracket screw engages evaporator bracket.
34.Tighten blower flange screws.
35.Apply Silicone sealant to casing joint and
insulating tape to seal pipes to casing.
36.Apply sealing tape around air duct joint.
37.Position evaporator unit in footwell.
38.Connect multiplugs to compressor relays and
secure harness P clip.
39.Connect Lucars (G, U, and R) to resistor unit
and (B) to motor.
40.Lift evaporator, insert pipes into aperture and
engage mounting studs.
41.Connect drain tube to pipe.
42.Fit grommet into aperture.
43.Lubricate NEW O rings with refrigerant oil and
fit to joints.
44.Carry out a functional check.
45.Using a backing spanner, engage high pressure
pipe and tighten union nut.
46.Using a backing spanner, engage low pressure
pipe and tighten union nut.
47.Fit nuts and secure evaporator casing to
mounting bracket.
48.Fit fascia duct bezel.
See fascia duct bezel;
Refit
49.Evacuate and recharge air conditioning system.
See Adjustment, refrigerant recovery
recycling recharging
50.Reconnect battery negative lead.
51.Perform leak test on disturbed joints
52.Carry out system test.
See Adjustment,
System test
WIRING HARNESS - SUPPLEMENTARY
Service repair no - 86.70.23
Remove
1.Remove evaporator.
See evaporator
2.Remove nut and release earth eyelet from
bulkhead.
3.Disconnect multiplug from compressor fly-lead.
4.Remove 4 ties securing harness to air
conditioning hoses.
5.Remove tie securing harness to engine harness.
6.Above chassis front crossmember, disconnect
multiplug from condenser fan fly-lead.
7.Disconnect multiplug from trinary switch.
8.Release ties securing harness to pipes.
9.Release harness. 
						

							AIR CONDITIONING
11
REPAIR
10.Remove fusebox cover.
11.Disconnect multiplug from main harness.
12.Remove screw securing earth eyelet to fusebox
bracket.
13.Pull harness from between centre console and
bulkhead.
14.Remove grommet from harness.
15.Remove P clip from harness.16.Extract harness from front of engine
compartment and pass through bulkhead into
footwell area. Remove air conditioning harness.
Refit
17.Position harness in footwell and route harness
into engine bay, follow evaporator and receiver
drier hoses to receiver drier.
18.Fit grommet and P clip to harness.
19.Position harness between centre console and
bulkhead with multiplugs in fusebox area.
20.Secure earth eyelet to fusebox bracket.
21.Connect multiplugs to main harness.
22.Position switch harness to RH side of console, fit
fusebox cover and secure with screws.
23.Connect multiplug to trinary switch and
condenser fan fly-lead.
24.Secure earth eyelet to fender.
25.Connect multiplug to compressor fly-lead.
26.Secure harness to air conditioning hoses with
ties.
27.Secure harness to engine harness with tie.
28.Fit evaporator.
See evaporator; Refit
29.Perform leak test on disturbed joints
30.Carry out system test.
See Adjustment,
System test 
						

							AIR CONDITIONING
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Air conditioning Nm lbf.ft
Compressor to mounting bracket 25..................................... 18
Compressor pipe flange bolts 10.......................................... 7
Receiver drier union bolts 6................................................ 4.5
Trinary pressure switch 11.................................................... 8
Pressure pipe union nuts - M16 14....................................... 10
Discharge pipe union nuts - M22 22..................................... 16
Suction pipe union nuts - M24 33.......................................... 24