Land Rover Defender Workshop Rover Manual

							AIRCONDITIONING
1
ADJUSTMENT
GENERAL
PRECAUTIONS
The refrigerant usedinthe airconditioning systemis
HFC (Hydrofluorocarbon) R134a.
WARNING:R134aisahazardous liquid
and when handled incorrectly cancause
serious injury.Suitable protective clothing
must beworn when carrying outservicing
operations onthe airconditioning system.
WARNING:R134aisodourless and
colourless. Donot handle ordischarge in
an enclosed area,orinany area where the
vapour orliquid cancome incontact withnaked
flame orhot metal. R134a isnot flammable, but
can form ahighly toxicgas.
WARNING: Donot smoke orweld inareas
where R134a isin use. Inhalation of
concentrations ofthe vapour cancause
dizziness, disorientation. uncoordination,
narcosis, nauseaorvomiting.
WARNING: Donot allow fluids otherthan
R134a orcompressor lubricanttoenter the
air conditioning system.Spontaneous
combustion mayoccur.
WARNING: R134asplashed onany part of
the body willcause immediate freezingof
that area. Alsorefrigerant cylindersand
replenishment trolleyswhendischarging will
freeze skintothem ifcontact ismade.
WARNING: Therefrigerant usedinan air
conditioning systemmustbereclaimed in
accordance withtherecommendations
given withaRefrigerant RecoveryRecycling
Recharging Station.
NOTE:Suitable protective clothing
comprises: Wraparound safetyglasses or
helmet, heatproof gloves,rubberapronor
waterproof overallsandrubber boots. REMEDIAL
ACTIONS
1. Ifliquid R134a strikestheeye, donot rub it.
Gently runlarge quantities ofeyewash overthe
eye toraise thetemperature. Ifeyewash isnot
available cool,clean water maybeused. Cover
eye with clean padandseek immediate medical
attention.
2. Ifliquid R134a issplashed onthe skin runlarge
quantities ofwater overthearea assoon as
possible toraise thetemperature. Carryoutthe
same actions ifskin comes intocontact with
discharging cylinders.Wrapaffected partsin
blankets orsimilar material andseek immediate
medical attention.
3. Ifsuspected ofbeing overcome byinhalation of
R134a vapour seekfresh air.Ifunconscious
remove tofresh air.Apply artificial respiration
and/or oxygen andseek immediate medical
attention.
NOTE: Duetoits low evaporating
temperature of-30 °C, R134a should be
handled withcare.
WARNING: Donot allow arefrigerant
container tobe heated byadirect flameor
to be placed nearanyheating appliance. A
refrigerant containermustnotbeheated above
50 °C.
WARNING: Donot leave acontainer of
refrigerant withoutitscap fitted. Donot
transport acontainer ofrefrigerant thatis
unrestrained, especiallyinthe boot ofacar.  
						

							82AIR
CONDITIONING
2 ADJUSTMENT
SERVICING
PRECAUTIONS
Care mustbetaken whenhandling refrigeration
system components. Unitsmustnotbelifted bytheir
hoses, pipesorcapillary lines.Hoses andlines must
not besubjected toany twist orstress. Ensure that
hoses arepositioned intheir correct runbefore fully
tightening thecouplings, andensure thatallclips and
supports areused. Torque wrenches ofthe correct
type must beused when tightening refrigerant
connections tothe stated value.Anadditional spanner
must beused tohold theunion toprevent twistingof
the pipe.
Before connecting anyhose orpipe ensure that
refrigerant oilisapplied tothe seat ofthe new 0ring
but nottothe threads.
Check theoiltrap forthe amount ofoil lost.
All protective plugsoncomponents mustbeleft in
place untilimmediately priortoconnection.
The receiver/drier containsdesiccant whichabsorbs
moisture. Itmust bepositively sealedatall times.
CAUTION: Whenevertherefrigerant
system isopened, thereceiver/drier must
be renewed immediately beforeevacuating
and recharging thesystem.
Use alcohol andaclean clothtoclean dirty
connections. Ensure thatallnew parts fittedaremarked foruse
with R134a.
Refrigerant oil
Use theapproved refrigerant lubricating oil-Nippon
Denso ND-OIL 8.
CAUTION: Donot use anyother typeof
refrigerant oil.
Refrigerant oileasily absorbs waterandmust notbe
stored forlong periods. Donot pour unused oilback
into thecontainer.
When renewing systemcomponents, addthe
following quantities ofrefrigerant oil:
Condenser 40ml
..........................................................
Evaporator 80ml
..........................................................
Pipe orhose 20ml
........................................................
Receiver/drier 20ml
...................................................... Total
quantity ofrefrigerant oilinsystem =140ml
A new compressor issealed andpressurised with
Nitrogen gas,slowly release thesealing cap,gas
pressure shouldbeheard torelease asthe seal is
broken.
NOTE: Anew compressor shouldalways
have itssealing capsinplace andthese
must notberemoved untilimmediately
prior tofitting
A new compressor issupplied withanoilfillof140ml.
A calculated quantityofoil must bedrained froma
new compressor beforefitting.
To calculate thequantity ofoil tobe drained:
1. Remove sealingplugsfromtheOLD
compressor.
2. Invert compressor andgravity drainoilinto
measuring cylinder.Rotatingthecompressor
clutch platewillassist complete draining.
3. Note thequantity ofoil drained (Yml).
4. Calculate thequantity (Qml)ofoil tobe drained
from theNEW compressor usingthefollowing
formula:
Xml -(Yml +20ml) =Qml
Rapid refrigerant discharge
When theairconditioning systemisinvolved in
accident damageandthecircuit ispunctured, the
refrigerant isdischarged rapidly.Therapid discharge
of refrigerant willalso result inthe loss ofmost ofthe
oil from thesystem. Thecompressor mustbe
removed andallthe remaining oilinthe compressor
drained andrefilled asfollows:
1. Gravity drainallthe oil,assist byrotating the
clutch plate(notthepulley).
2. Refill thecompressor with90ml ofnew
refrigerant oil.
3. Plug theinlet andoutlet ports.
Servicing Equipment
The following equipment isrequired forfull servicing
of the airconditioning system.
Recovery, recyclingandcharging station
Leak detector
Thermometer +20°C to -60 °C
Safety goggles andgloves 
						

							AIRCONDITIONING
3
ADJUSTMENT
REFRIGERANT
RECOVERY,RECYCLING,
RECHARGING
WARNING: Theairconditioning systemis
charged withahigh pressure, potentially
toxic refrigerant. Repairsorservicing must
only becarried outbyanoperator familiarwith
both thevehicle system andthecharging and
testing equipment.
All operations mustbecarried outina
well-ventilated areaaway fromopen flame and
heat sources.
Always wearsafety goggles andgloves when
opening refrigerant connections.
WARNING: Weareyeand hand safety
protection. Openconnections slowlyin
case liquid orpressure ispresent. Allowto
bleed offslowly.
CAUTION: Overcharging airconditioning
system willcause excessive head
pressure.
An airconditioning portableRefrigerant Recovery
Recycling Recharging Stationforuse with R134a
refrigerant incorporates allthe features necessary to
recover refrigerant R134afromtheairconditioning
system, tofilter andremove moisture, toevacuate and
recharge withthereclaimed refrigerant. Theunitcan
also beused forperformance testingandair
conditioning systemanalysis.
The operator mustadhere tothe equipment
manufacturers instructions.
Recovery andrecycling
1. Connect aRefrigerant Stationtothe high and
low pressure servicing connections.
2. Operate therefrigerant recoverysystem
according tothe manufacturers instructions.
3. Measure theamount ofoil discharged fromthe
system. Addanequal amount ofnew refrigerant
oil tocompressor beforeevacuation sequence.
WARNING: Refrigerant mustalways be
recycled beforereuse,toensure thatthe
purity ofthe refrigerant ishigh enough for
safe useinthe airconditioning system.Recycling
should alwaysbecarried outwith equipment
which isdesign certified byUnderwriter
Laboratory Inc.forcompliance withSAE-J1991.
Other equipment maynotrecycle refrigerant to
the required levelofpurity.
A R134a Refrigerant RecoveryRecycling
Recharging Stationmustnotbeused withany
other typeofrefrigerant.
Refrigerant R134afromdomestic andcommercial
sources mustnotbeused inmotor vehicle air
conditioning systems.
Evacuation andrecharging
1. Add refrigerant oiltocompressor ifnecessary.
2. Renew thereceiver/drier.
CAUTION: Whenamajor repair hasbeen
carried out,aleak testshould becarried
out using inertgas.
3. Connect aRefrigerant Stationtothe high and
low pressure servicing connections.
CAUTION: Whenevertherefrigerant
system isopened, thereceiver/drier must
be renewed immediately beforeevacuating
and recharging thesystem.
4. Operate therefrigerant evacuation system
according tothe manufactures instructions.
NOTE:Ifthe vacuum readingisbelow
700mmHg after15minutes, suspectaleak
in the system. Partially recharge the
system andcheck forleaks using anelectronic
leak tester. Check suction linesfirst,thenrunthe
compressor for5minutes andthen check thehigh
pressure lines.
CAUTION: Thesystem mustbeEvacuated
immediately beforerecharging
commences. Delaybetween Evacuation
and Recharging isnot permitted.  
						

							82AIR
CONDITIONING
4 ADJUSTMENT
5.
Operate therefrigerant recharging system
according tothe manufactures instructions.
Refrigerant tocharge system is1.1 kg.
6. Ifthe fullcharge hasnotbeen accepted bythe
system, starttheengine andrunitat 1500
rev/min foraminimum of2minutes.
Switch onthe airconditioning system,openthe
vehicle windows, setthe temperature controlto
cold andswitch theblower tomaximum speed.
7. Consult Refrigerant StationManual forcorrect
procedure tocomplete thecharge.
8. Carry outtheairconditioning system
performance test. LEAK
TESTSYSTEM
The following instructions refertoan electronic type
Refrigerant LeakDetector foruse with R134a, which
is the safest andmost sensitive.
CAUTION: Whenamajor repair hasbeen
carried out,aleak testshould becarried
out using aninert gas(see below).
1. Place thevehicle inawell ventilated areabut
free from draughts, asleakage fromthesystem
could bedissipated withoutdetection.
2. Follow theinstructions issuedbythe
manufacturer ofthe particular leakdetector
being used.
3. Commence searchingforleaks bypassing the
detector probearound alljoints andcomponents,
refrigerant gasisheavier thanair.
4. Insert theprobe intoanairoutlet ofthe
evaporator orinto theevaporator draintube.
Switch theairconditioning bloweronand offat
intervals often seconds. Anyleaking refrigerant
will begathered inby the blower anddetected.
5. Insert theprobe between themagnetic clutch
and compressor tocheck theshaft sealfor
leaks.
6. Check allservice valveconnections, valveplate,
head andbase platejoints andback sealplate.
7. Check thecondenser forleaks atthe pipe
unions.
8. Ifany leaks arefound, thesystem mustbe
discharged beforerectification.
9. Rectify anyleaks andrecheck forleaks during
evacuation priortocharging.
Leak testusing inertgas
Use Nitrogen orHelium gas.
1. Connect gaslinetorecharging station.
2. Pressurise systemto3bar.
3. Carry outleak testasabove. 
						

							AIRCONDITIONING
5
ADJUSTMENT
AIR
CONDITIONING SYSTEM-PERFORMANCE
TEST
WARNING: R134aishazardousSee
Repair, General Precautions
Carryoutthis test with bonnet anddoors orwindows
open, airconditioning switchedon,temperature
control settocold andblower atmaximum speed.Set
the airsupply control tosupply freshair.
1. Close lowpressure valveonrefrigerant station.
2. Close highpressure valveonrefrigerant station.
3. Connect aRefrigerant Stationtothe high and
low pressure servicing connections. 4.
Insert drybulb thermometer intocold airoutlet
and position dryand wetbulb thermometer close
to outside airinlet.
Do not spill water fromthewet thermometer
(psychrometer).
5. Start engine andrunitat 1500 rev/min for10
minutes withairconditioning switchedon.
6. Read bothpressure gaugesandthermometers.
Check readings againsttablebelow with
humidity between 60%and80%.
7. Switch offairconditioning, stopengine,
disconnect testequipment.
Performance range
Intake temperature Outlettemperature Lowpressure Highpressure
20 -24 ° C4 -10° C 18 -28 lbf/in 2
213-299 lbf/in 2
1.2 -1.9 bar 14.7-20.6 bar
25 -29 ° C9 -19° C 27 -37 lbf/in 2
256-341 lbf/in 2
1.9 -2.6 bar 17.6-23.5 bar
30 -35 ° C2 0-27° C 33 -47 lbf/in 2
299-384 lbf/in 2
2.3 -3.2 bar 20.6-26.5 bar
Table 1
Ambient CompoundGauge HighPressure
Temperature ReadingsGaugeReadings
° C °F bar lbf/in2
bar lbf/in2
16 601,03-1,4 15-206,9-10,3 100-150
26,7 801,4-1,72 20-259,6-13,1 140-190
38 1001,72-2,1 25-3012,4-15,5 180-225
43,5 1102,1-2,4 30-3514,8-17,2 215-250  
						

							82AIR
CONDITIONING
6 ADJUSTMENT
SYSTEM
TEST
1. Place thevehicle inaventilated, shadedarea
free from excessive draught,withthedoors and
windows open.
2. Check thatthesurface ofthe condenser isnot
restricted withdirt,leaves, flies,etc.Donot
neglect tocheck thesurface between the
condenser andtheradiator. Cleanasnecessary.
3. Switch onthe ignition andtheairconditioner air
flow control. Checkthattheblower isoperating
efficiently atlow, medium andhigh speeds.
Switch offthe blower andtheignition.
4. Check thattheevaporator condensate drain
tubes areopen andclear.
5. Check thetension ofthe compressor drivingbelt,
and adjust ifnecessary.
6. Inspect allconnections forthe presence of
refrigerant oil.Ifoil isevident, checkforleaks,
and repair asnecessary.
NOTE: Thecompressor oilissoluble in
Refrigerant R134aandisdeposited when
the refrigerant evaporates fromaleak.
7. Start theengine.
8. Set thetemperature controlstocold andswitch
the airconditioner blowercontrol onand off
several times,checking thatthemagnetic clutch
on the compressor engagesandreleases each
time.
9. With thetemperature controlatmaximum
cooling andtheblower control athigh speed,
warm upthe engine andfastidleat1000
rev/min.
10. Repeat at1800 rev/min.
11. Gradually increasetheengine speedtothe high
range andcheck thesight glass atintervals.
12. Check forfrosting onthe service valves.
13. Check thehigh pressure hosesandconnections
by hand forvarying temperature. Low
temperature indicatesarestriction orblockage at
that point.
14. Switch offthe airconditioning blowerandstop
the engine.
15. Ifthe airconditioning equipmentisstill not
satisfactory, carryoutapressure testas
previously describedinthis section. PRECAUTIONS
INHANDLING REFRIGERANT
LINES
WARNING: Weareyeand hand protection
when disconnecting components
containing refrigerant. Plugallexposed
connections immediately.
1. When disconnecting anyhose orpipe
connection thesystem mustbedischarged ofall
pressure. Proceedcautiously, regardlessof
gauge readings. Openconnections slowly,
keeping handsandface wellclear, sothat no
injury occurs ifthere isliquid inthe line. If
pressure isnoticed, allowitto bleed offslowly.
2. Lines, flexible endconnections andcomponents
must becapped immediately theyareopened to
prevent theentrance ofmoisture anddirt.
3. Any dirtorgrease onfittings mustbewiped off
with aclean alcohol dampened cloth.Donot use
chlorinated solventssuchastrichloroethylene. If
dirt, grease ormoisture cannotberemoved from
inside thehoses, theymust bereplaced with
new hoses.
4. Allreplacement componentsandflexible end
connections mustbesealed, andonly opened
immediately priortomaking theconnection.
5. Ensure thecomponents areatroom temperature
before uncapping, toprevent condensation of
moisture fromtheairthat enters.
6. Components mustnotremain uncapped for
longer than15minutes. Inthe event ofdelay, the
caps must befitted.
7. Receiver/driers mustnever beleft uncapped as
they contain SilicaGelcrystals whichwillabsorb
moisture fromtheatmosphere. Areceiver/ drier
left uncapped mustnotbeused, fitanew unit.
8. The compressor shaftmustnotberotated until
the system isentirely assembled andcontains a
charge ofrefrigerant.
9. Anew compressor containsaninitial charge of
refrigerant oil.The compressor alsocontains a
holding chargeofgas when received which
should beretained byleaving theseals inplace
until thepipes arere-connected.
10. The receiver/drier shouldbethe last component
connected tothe system toensure optimum
dehydration andmaximum moistureprotection of
the system. 
						

							AIRCONDITIONING
7
ADJUSTMENT
11.
Allprecautions mustbetaken toprevent
damage tofittings andconnections. Slight
damage couldcause aleak withthehigh
pressures usedinthe system.
12. Always usetwowrenches ofthe correct size,
one oneach fitting when releasing and
tightening refrigeration unions.
13. Joints andOrings should becoated with
refrigeration oiltoaid correct seating. Fittings
which arenotlubricated withrefrigerant oilare
almost certain toleak.
14. Alllines must befree ofkinks. Theefficiency of
the system isreduced byasingle kinkor
restriction.
15. Flexible hosesshould notbebent toaradius
less than 90mm radius.
16. Flexible hosesshould notbewithin 100mm of
the exhaust manifold.
17. Completed assemblies mustbechecked for
refrigeration linestouching metalpanels. Any
direct contact oflines andpanels transmits noise
and must beeliminated. PERIODIC
MAINTENANCE
Routine servicing, apartfromvisual checks, isnot
necessary. Thevisual inspections areasfollows:
Condenser With awater hoseorair line, clean thefins ofthe
condenser toremove flies,leaves, etc.Check thepipe
connections forsigns ofoil leakage.
CompressorCheck pipeconnections forsigns ofoil leakage.
Check flexible hosesforswelling. Examine the
compressor beltfortightness andcondition.
Sight glass
Examine thesight glass forbubbles withthesystem
operating. Checkconnections forleakage.
EvaporatorExamine therefrigeration connections atthe unit.  
						

							AIRCONDITIONING
1
REPAIR
COMPRESSOR Service
repairno-82.10.20
Remove 1. Disconnect battery.
2. Recover refrigerant fromairconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
3.Remove compressor drivebelt.See
Compressor drivebelt
4.Disconnect highpressure pipefrom compressor.
5. Disconnect lowpressure pipefrom compressor.
6. Remove Oring from each flange.
7. Disconnect compressor clutchharness
multi-plug.
8. Remove compressor frommounting bracket
studs. Refit
9. Ifa new compressor isto be fitted firstdrain oil
from newcompressor. Drainandmeasure oil
from oldcompressor. Measurenewoilequal to
amount fromoldcompressor, add30mlextra to
this amount andrefill new compressor through
outlet port.
10. Locate compressor overmounting bracketstuds.
11. Reconnect compressor clutchharness
multi-plug.
12. Fitnew Orings tohigh andlowpressure hose
flanges, lubricate withrefrigerant oil.
13. Fithigh andlowpressure hoses.
14. Fitcompressor drivebelt
SeeCompressor
drive belt.
15.Evacuate andrecharge airconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
16.Reconnect battery.
17. Perform aleak testondisturbed joints.
18. Carry outafunctional check.   
						

							82AIR
CONDITIONING
2 REPAIR
COMPRESSOR
DRIVEBELT
Service repairno-82.10.02
Remove 1. Disconnect battery.
2. Remove auxiliarydrivebelt
SeeELECTRICAL,
Repair, Auxiliary drivebelt.
3.Remove 3nuts securing drivebeltguard to
compressor retainingstuds.
4.Slacken 3belt tensioner retainingbolts.
5. Remove compressor drivebelt.Mark direction
on belt ifrefitting. Refit
6. Fitcompressor drivebelt.
7. Fitdrive beltguard.
8. Fittorque metertocentre oftensioner, applyand
hold atorque of
35Nm (26lbf/ft).
9.Tighten tensioner retainingbolts.
10. Rotate crankshaft 2full turns.
11. Reapply andhold atorque of
35Nm (26lbf/ft)
totensioner, thenfullyslacken andretighten
tensioner retainingboltsto
25Nm (18lbf/ft).
12. Fitauxiliary drivebeltSeeELECTRICAL,
Repair, Auxiliary drivebelt.
13.Reconnect battery.   
						

							AIRCONDITIONING
3
REPAIR
CONDENSER
FANAND MOTORS
Service repairno-82.15.08
Remove 1. Disconnect battery.
2. Remove 6screws andliftgrille panel from
vehicle.
3. Disconnect fanmotor multi-plugs andrelease
harness retaining clips.
4. Remove nutand washers andwithdraw fan
blade frommotor driveshaft.
5. Remove 2retaining screws,releasemotorfan
from shroud support brackets andfeed motor
multi-plug leadthrough appropriate aperture.
Refit 6. Feed motor leadthrough fanshroud.
7. Fitmotor tofan shroud support brackets.
8. Reconnect fanlead multi-plug andsecure with
retaining clips.
9. Fitfan blade tomotor driveshaft.
10. Fitgrille panel.
11. Reconnect battery. CONDENSER Service
repairno-82.15.07
Remove 1. Disconnect battery.
2. Recover refrigerant fromairconditioning system
SeeAdjustment, Refrigerantrecovery,
recycling, recharging.
3.Remove 6screws andliftgrille panel from
vehicle .
4.Disconnect condenserfanmotor lead
multi-plugs.
5. Disconnect receiver/drier dualpressure switch
multi-plug.
6. Disconnect condenserlowpressure pipeat
compressor.
7. Disconnect highpressure hose/pipe at
evaporator.