1995 LAND ROVER DISCOVERY Workshop Manual

82AIR CONDITIONING
4
REPAIR AIR CONDITIONING SWITCH
Service repair no - 82.20.29
Remove
1.Remove fascia centre louvre vent panel.
See
CHASSIS AND BODY, Repair, Dash Panel
Central Louvre Panel
2.Disconnect multiplug from switch
3.From the rear, push switch out of panel.
Refit
4.Reverse removal procedure.DUAL PRESSURE SWITCH
Service repair no - 82.20.20
Remove
1.Disconnect battery negative lead.
2.Recover refrigerant from system.
See
Adjustment, Refrigerant Recovery Recycling
Recharging
3.Disconnect multiplug from switch.
4.Unscrew switch from adapter. Use a second
wrench to support adapter.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
5.Remove 'O' ring from switch.
Refit
6.Reverse removal procedure. Lubricate new 'O'
ring with refrigerant oil and fit to switch.
7.Screw switch into adapter and tighten to
11 Nm.
8.Evacuate and recharge air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging

AIR CONDITIONING
5
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Disconnect battery negative lead.
2.Recover refrigerant from air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging
3.Remove screws retaining centre panel to fan
cowl
4.Remove centre panel.
V8i engine illustrated
5.Remove 2 bolts securing hose flanges to
compressor.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.6.Disconnect high pressure hose from
compressor.
7.Disconnect low pressure hose from compressor.
8.Remove 'O' ring from each flange.
9.Disconnect electrical lead from compressor
clutch.
10.Release drive belt from compressor pulley.
See
ENGINE, Repair, Drive Belt
11.Remove 4 bolts securing compressor to
mounting bracket.
12.Remove compressor from mounting bracket.
Refit
13.New compressor to be fitted: Drain oil from new
compressor outlet port. Drain and measure oil
from old compressor. Measure new oil equal to
amount drained from old compressor, add 30 ml
extra to this amount and refill new compressor
through outlet port.
14.Locate compressor in mounting bracket, fit bolts.
Tighten to
25 Nm.
15.Connect electrical lead to compressor clutch.
16.Fit new 'O' rings to high and low pressure hose
flanges, lubricate with refrigerant oil.
17.Engage hose flanges, fit bolts. Tighten to
10
Nm.
18.Fit compressor drive belt.See ENGINE, Repair,
Drive Belt
19.Fit centre panel to fan cowl.
20.Evacuate and recharge air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging
21.Perform a leak test on disturbed joints.
22.Carry out a functional check.

82AIR CONDITIONING
6
REPAIR CONDENSER
Service repair no - 82.15.07
Remove
1.Disconnect battery negative lead.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
2.Recover refrigerant from system.
See
Adjustment, Refrigerant Recovery Recycling
Recharging
3.Remove front grille panel.
4.Remove battery.
See ELECTRICAL, Repair,
Battery
5.Remove radiator and oil coolers assembly.See
COOLING SYSTEM, Repair, Radiator
6.Disconnect high and low pressure pipes at
condenser unions.
7.Discard 'O' ring seal from each union.
8.Remove 2 bolts securing condenser to body.
9.Pull condenser into radiator area.
10.Disconnect multiplug from each fan lead.
11.Remove condenser assembly.
Do not carry out
further dismantling if component is removed
for access only.
Blank off inlet and outlet ports.

AIR CONDITIONING
7
REPAIR
12.Disconnect receiver/drier pipes at condenser
unions.
13.Remove retaining bracket from side pipe.
14.Remove LH pipe from condenser and discard 'O'
ring.
15.Remove 2 screws securing receiver/drier
bracket.
16.Release pipes from lower clips and remove
receiver/drier assembly.
17.Remove 'O' ring from RH pipe
18.Remove 2 screws securing lower end of each
fan motor.
19.Remove 2 bolts and remove condenser lower
mounting bracket.
20.Remove 2 bolts and securing condenser upper
mounting bracket.
21.Remove upper mounting bracket and fan motor
assembly.
22.Remove 2 screws securing each side mounting
bracket and remove the brackets.
23.Transfer parts removed to new condenser.
24.Add 40 ml of refrigerant oil to new compressor to
compensate for oil loss.
Refit
25.Reverse removal procedure. 3 to 11.
26.Evacuate and recharge air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging
27.Carry out leak test on disturbed joints.See
Adjustment, Leak Test System
28.Check air conditioning operation by carrying out
a System Test.
See Adjustment, System Test
CONDENSER FANS AND MOTORS
Service repair no - 82.15.01 - Motor
Service repair no - 82.15.03 - Fan
Remove
1.Remove condenser assembly.
See Condenser
2.Remove 4 bolts securing fan cowl to condenser.
3.Remove 3 bolts securing fan motor to cowl.
4.Remove fan motor assembly.
5.Remove 3 screws securing fan blades to motor.
6.Remove fan blades.
Refit
7.Reverse removal procedure. Ensuring that wiring
is clipped and no fouling of fan blade can occur.

82AIR CONDITIONING
8
REPAIR HEATER AND COOLER UNIT
Service repair no - 86.25.21
WARNING: All work involving the service
and maintenance of air conditioning
requires special equipment, knowledge,
experience and a full awareness and adherence to
safety precautions.
Remove
1.Disconnect battery negative lead.
2.Drain engine coolant.
See COOLING SYSTEM,
Adjustment, Coolant
3.Recover refrigerant from air conditioning system.
See Adjustment, Refrigerant Recovery
Recycling Recharging
4.Remove fascia panel assembly.See CHASSIS
AND BODY, Repair, Dash Panel Assembly
5.Release clips and disconnect coolant hoses
from heater pipes.
6.Remove securing bolt and disconnect low
pressure pipe from evaporator.
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
7.Release 'P' clip retaining high and low pressure
pipes.
8.Remove securing bolt and disconnect high
pressure pipe from evaporator.
9.Discard 'O' ring seals.

AIR CONDITIONING
9
REPAIR
10.Disconnect multiplug connecting heater to
blower unit, remove 3 screws and remove
blower unit.
11.Remove 5 screws securing casing to bulkhead
and tunnel.
12.Remove 2 securing bolts and remove centre
console front mounting bracket.
13.Disconnect 2 drain tubes..
14.Ease heater and cooler unit from its location and
remove from vehicle.
Refit
15.Ease heater and cooler unit into position.
16.Fit retaining bolts finger tight. Tighten in
sequence, centre and top bolts and then the
bottom bolt.
17.Reverse removal procedure.
18.Use new 'O' rings and lubricate with refrigerant
oil.
19.Evacuate and recharge system.
See
Adjustment, Refrigerant Recovery Recycling
Recharging
20.Leak test any disturbed joints.See Adjustment,
Leak Test System
21.Perform a functional check.EVAPORATOR AND EXPANSION VALVE
Service repair no - 86.25.20 - Evaporator
Service repair no - 86.25.01 - Expansion valve
Remove
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
1.Remove heater and cooler unit.
See Heater
and Cooler Unit

82AIR CONDITIONING
10
REPAIR 2.Disconnect 2 Lucar connectors from thermostat.
3.Position wiring aside.
4.Remove 2 screws securing heater pipe bracket
and position pipes aside.
5.Remove 10 clips retaining upper and lower
casings.
6.Remove 5 screws retaining upper casing.
7.Remove lower casing and evaporator.
8.Remove 4 clips securing evaporator top cover.
9.Remove evaporator top cover.
10.Remove thermostat sensor from evaporator
matrix.
11.Remove evaporator assembly from lower casing.
12.Remove bulkhead seal from case.
Expansion valve
13.Remove insulation from evaporator and
expansion valve connections.
14.Remove expansion valve sensor retaining clip.
15.Unscrew 2 pipe unions. Discard 'O' ring seals.
CAUTION: Use a second wrench to
support pipe adapters and plug
connections.
16.Remove expansion valve.
17.Unscrew pipe union. Discard 'O' ring seal.
18.Remove evaporator pipe.
Refit
19.Reverse removal procedure. Use new 'O' rings,
insulation and bulkhead seal.
NOTE: Use refrigerant oil on all 'O' rings
and mating surfaces. Tighten connection
See Specifications, torque, Torque Values
20.Wrap all exposed metal at hose connections with
prestite tape.
21.Evacuate and recharge system.
See
Adjustment, Refrigerant Recovery Recycling
Recharging
22.Leak test any disturbed joints.See Adjustment,
Leak Test System
23.Perform a functional check.
24.Disconnect service unit.

AIR CONDITIONING
11
REPAIR THERMOSTAT
Service repair no - 86.25.50
Remove
1.Remove heater and cooler unit.
See Heater
and Cooler Unit
2.Remove lower cover and evaporator.See
Evaporator and Expansion Valve
3.Remove 5 clips and screw securing evaporator
top cover.
4.Remove evaporator top cover.
5.Remove thermostat sensor from evaporator
matrix.
6.Remove 2 screws securing sensor unit.
7.Remove thermostat and insulation.
Refit
8.Reverse removal procedure.
CAUTION: The thermostat insulation must
be installed in the ORIGINAL POSITION in
the evaporator.EVAPORATOR/BLOWER MOTOR ASSEMBLY -
REAR
Service repair no - 82.26.01
Remove
1.Recover refrigerant from system.
See
Adjustment, refrigerant recovery recycling
recharging
WARNING: Wear eye and hand protection
when disconnecting components
containing refrigerant. Plug all exposed
connections immediately.
2.Remove evaporator to alpine light duct.
See
evaporator to alpine light duct
3.Remove LH rear mud flap.See CHASSIS AND
BODY, Repair, mud flap - rear - lh
4.Clean area around low and high pressure air
conditioning pipe unions, beneath rear wheel
arch, to prevent any risk of dirt entering the
system.
5.Loosen and disconnect high and low pressure
air conditioning pipe unions beneath rear wheel
arch.
6.Remove and discard 'O' rings from pipe unions.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
CAUTION: Plug exposed connections
immediately.