1999 LAND ROVER DEFENDER air condition

PANEL REPAIRS
9
SEALING AND CORROSION PROTECTION Stone Chip Resistant Paint/Primer
Re-treat all areas protected with factory-applied
anti-chip primer with suitable approved material in
repair.
Inspections during Maintenance Servicing
It is a requirement of the Land Rover Corrosion
Warranty that the vehicle body is checked for
corrosion by an authorised Land Rover dealer at least
once a year, to ensure that the factory-applied
protection remains effective.
Service Job Sheets include the following operations to
check bodywork for corrosion:
With the vehicle on a lift, carry out visual
check of underbody sealer for damage.
With the vehicle lowered, inspect exterior
paintwork for damage and body panels for
corrosion.
NOTE: Wash the vehicle and ensure that it
is free from deposits prior to inspection. It
is part of the owner’s responsibility to
ensure that the vehicle is kept free of
accumulations of mud which could accelerate the
onset of corrosion. The Dealer MUST wash the
vehicle prior to inspection of bodywork if the
customer has offered it in a dirty condition, and
pay special attention to areas where access is
difficult.
NOTE: The checks described above are
intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or sound
deadening materials when checking the vehicle
for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or
spot lamp, visually check for the following:
Corrosion damage and damaged
paintwork, condition of underbody sealer
on front and rear lower panels, sills and
wheel arches.
Damage to underbody sealer on main floor
and chassis members. Corrosion in areas
adjacent to suspension mountings and fuel
tank fixings.
NOTE: The presence of small blisters in
PVC underbody sealer is acceptable,
providing they do not expose bare metal.
Special attention must be paid to signs of damage
caused to panels or corrosion material by incorrect
jack positioning.
It is essential to follow the correct jacking and lifting
procedures.See GENERAL INFORMATION DATA,
Information section.
With the vehicle lowered, visually check for evidence
of damage and corrosion on all painted areas, in
particular the following:
Front edge of bonnet.
Visible flanges in engine compartment and
boot.
Lower body and door panels.
Where bodywork damage or evidence of corrosion is
found during inspection, rectify this as soon as is
practicable, both to minimise the extent of the damage
and to ensure the long term effectiveness of the
factory-applied corrosion protection treatment. Where
the cost of rectification work is the owner’s
responsibility, the Dealer must advise the owner and
endorse the relevant documentation accordingly.
Where corrosion has become evident and is
emanating from beneath a removable component
(e.g. trim panel, window glass, seat etc.), remove the
component as required to permit effective rectification.
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PANEL REPAIRS
1
REPAIR WING LOWER FRONT
Remove
1.Disconnect both battery leads, negative lead
first. system.
2.Remove wheel arch eyebrow.
3.Remove wheel arch liner.
4. RH side:Remove aerial.
5.Remove air intake hose.
6.Remove bolts securing lower wing.
Refit
7.Prepare and clean panel joint faces.
8.Reverse removal procedure.HEADLAMP MOUNTING PANEL
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect all ECUs.
3.Remove radiator.See COOLING SYSTEM,
Repair.
4.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
5.Remove headlamp.See ELECTRICAL,
Repair.
6. LH side:Remove screen washer bottle.See
WIPERS AND WASHERS, Repair.
7. RH side:Position PAS reservoir aside.
8.Remove bolts and release welds securing panel,
remove panel.
Refit
9.Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
10.Reverse removal procedure.
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77PANEL REPAIRS
2
REPAIR WING UPPER - LH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove receiver drier.See AIR
CONDITIONING, Repair.
7.Remove relevant A/C pipes.
8.Remove relevant heater intake pipes.
9.Remove screen washer bottle.
10.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
11.Remove bolts and release welds securing panel,
remove panel.
Refit
12.Prepare and clean panel joint faces.
13.Reverse removal procedure.
14.Align headlamps.See ELECTRICAL,
Adjustment.WING UPPER - RH
Remove
1.Disconnect both battery leads, negative lead
first.
2.Remove headlamp.See ELECTRICAL,
Repair.
3.Remove headlamp mounting panel.See this
Section.
4.Remove radiator.See COOLING SYSTEM,
Repair.
5.Recover refrigerant from A/C system.See AIR
CONDITIONING, Repair.
6.Remove relevant A/C pipes.
7.Position PAS reservoir aside.
8.Remove wheel arch liner.See CHASSIS AND
BODY, Repair.
9.Remove aerial.
10.Remove vacuum solenoid valve.
11.Release clips securing coolant reservoir.
12.Remove bolts and release welds securing panel,
remove panel.
Refit13.Prepare and clean panel joint faces.
NOTE: LH panel shown
14.Reverse removal procedure.
15.Align headlamps.See ELECTRICAL,
Adjustment.
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82 - AIR CONDITIONING
CONTENTS
Page
ADJUSTMENT
REFRIGERANT RECOVERY, RECYCLING, RECHARGING 1.............................
REPAIR
COMPRESSOR 1...................................................................................................
MOTOR - CONDENSER FAN 2..............................................................................
RECEIVER DRIER 2...............................................................................................
RELAY - TEMPERATURE CONTROL - FROM 02MY 3.........................................
EVAPORATOR 4....................................................................................................
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AIR CONDITIONING
1
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
Service repair no - 82.30.02
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.
WARNING: All operations must be carried
out in a well ventillated area away from
open flame and heat sources.
WARNING: Wear eye and hand safety
protection.
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 R134a refrigerant 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
manufacturer’s instructions.
Refrigerant Recovery
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
NOTE: Operate the refrigerant station in
accordance with the manufacturers
instructions.
5.Turn Process switch to correct position.
6.Turn Main switch to’ON’.
7.Allow station to recover refrigerant from system.8.Close valves on refrigerant station.
9.Turn Main switch to’OFF’.
10.Close valves on connectors.
11.Disconnect high and low pressure hoses from
connectors.
12.Fit dust caps to connectors.
13.Open tap at rear of station to drain refrigerant oil
recovered from system.
14.Measure and record quantity of refrigerant oil
recovered from system.
15.Close tap at rear of station.
Evacuation
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
1.Remove dust caps from high and low pressure
connectors.
2.Connect high and low pressure hoses to
appropriate connections.
3.Open valves on connectors.
4.Turn valves on refrigerant station to correct
positions.
5.Turn Process switch to correct position.
6.Turn Main switch to’ON’.
7.Allow station to evacuate system.
NOTE: If the vacuum reading is below
700mmHg 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. Next check the high
pressure lines.
NOTE: The system must be evacuated
immediately before recharging
commences. Delay between evacuation
and recharging is not permitted.
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82AIR CONDITIONING
2
ADJUSTMENT Recharging
WARNING: Refrigerant must always be
recycled before re-use, to ensure that the
purity of the refrigerant is high enough for
safe use within 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 re-cycle the
refrigerant to the required level of purity.
WARNING: A R134a Refrigerant Recovery
Recycling Recharging station must not be
used with any other type of refrigerant.
WARNING: R134a refrigerant from
domestic and commercial sources must
not be used in motor vehicle air
conditioning systems.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
1.Close valves on refrigerant station.
2.Close valve on oil charger.
3.Disconnect yellow hose from refrigerant station.
4.Remove lid from oil charger.
5.Pour correct quantity of refrigerant oil into oil
charger.
6.Fit lid to oil charger.
7.Connect yellow hose to refrigerant station.
8.Open valve on oil charger.
9.Move pointer on refrigerant gauge to mark
position of refrigerant drop.
10.Slowly open correct valve on refrigerant station
and allow vacuum to pull refrigerant into system.
11.Close valve on refrigerant station when correct
amount of refrigerant has been drawn into air
conditioning system.
12.If the full charge is not accepted by the system,
start the engine and run it at 1,500 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 the
blower switch to maximum.
13.Consult Refrigerant station instruction manual for
correct procedure to complete the charge.
14.Turn Main switch to’OFF’.
15.Close valves on connectors.
16.Disconnect high and low pressure hoses from
connectors.
17.Fit dust caps to connectors.
18.Carry out performance test on air conditioning
system.
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AIR CONDITIONING
1
REPAIR COMPRESSOR
Service repair no - 82.10.20
Remove
1.Remove engine acoustic cover.See ENGINE ,
Repair.
2.Depressurise A/C system.See Adjustment.
3.Remove auxiliary drive belt.See
ELECTRICAL, Repair.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
10.Position compressor to mounting bracket and
tighten bolts to25 Nm (18 lbf.ft).
11.Remove caps from compressor and pipe
connections.
12.Clean compressor and pipe connections.
13.Lubricate new’O’rings with refrigerant oil and fit
to compressor.
14.Position A/C pipes to compressor and tighten
bolts to9 Nm (7 lbf.ft).
15.Connect multiplug to compressor.
16.Position top hose and secure with clips.
17.Refill cooling system.See COOLING SYSTEM,
Adjustment.
18.Fit auxiliary drive belt.See ELECTRICAL,
Repair.
19.Recharge A/C system.See Adjustment.
20.Fit engine acoustic cover.See ENGINE ,
Repair.
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82AIR CONDITIONING
2
REPAIR MOTOR - CONDENSER FAN
Service repair no - 82.15.01
Remove
1.Remove 6 screws and remove radiator grille.
2.Disconnect fan multiplug and release multiplug
holder from retaining clip.
3.With assistance remove 4 nuts and bolts
securing motor to condenser.
4.Remove motor.
Refit
5.Position motor to condenser and with assistance
tighten nuts and bolts to8 Nm (6 lbf.ft).
6.Connect motor multiplug.
7.Position radiator grille and secure with screws.RECEIVER DRIER
Service repair no - 82.17.03
Remove
1.Recover refrigerant from A/C system.See
Adjustment.
2.Remove 2 bolts securing pipe unions to receiver
drier.
3.Release pipes and discard’O’rings.
CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
4.Remove 2 bolts securing receiver drier mounting
bracket to chassis.
5.Remove receiver drier, slacken clamp bolt and
remove bracket.
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