torque LAND ROVER DISCOVERY 1995 Workshop Manual

HEATING AND VENTILATION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
METRIC
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................
Torque values above apply to all screws and bolts used unless otherwise specified.

AIR CONDITIONING
1
FAULT DIAGNOSIS AIR CONDITIONING FAULTS
FAULT CAUSE REMEDY
1. Incorrect voltage. 1. Check voltage.
A.2. Open or defective fuse or relay. 2. Check and replace as necessary.
BLOWER3. Loose wire connection including 3. Check system wires; tighten
MOTORground. all connections.
INOPERATIVE4. Switch open or defective. 4. Replace switch.
OR SLOW5. Tight, worn, or burnt motor 5. Replace motor.
RUNNINGbearings.
6. Open rotor windings. 6. Replace motor.
7. Worn motor brushes. 7. Replace motor.
8. Shaft binding-blade misaligned. 8. Check alignment. Repair or replace
as necessary.
9. Defective resistors 9. Rectify or replace.
1. Incorrect voltage. 1. Check voltage.
2. Open or defective fuse or relay. 2. Check and replace as necessary.
B.3. Defective thermostat control or 3. Replace thermostat or
COMPRESSORpressure switch. pressure switch.
CLUTCH4. Shorted or open field coil. 4. Replace coil.
INOPERATIVE5. Bearing seized (clutch will not 5. Replace clutch pulley assembly.
disengage).
6. Refrigeration circuit problem causing
heavy load and excessive drive
torque.6. Check and rectify.
1. Incorrect alignment. 1. Check alignment; repair as
necessary.
2. Loose belt. 2. Adjust to proper tension.
C.3. Compressor not mounted securely. 3. Repair as necessary.
COMPRESSOR4. Bearing in clutch-pulley 4. Remove clutch and replace
CLUTCHassembly not pressed in. clutch pulley assembly.
NOISY5. Low voltage to clutch. 5. Check connections and voltage.
6. Clutch will not spin freely. 6. Refer to B5 above.
7. Oil on clutch face. 7. Check compressor seals for leaks.
8. Slipping clutch. 8. Refer to C5 above. Then check air
gap.
9. Overloaded or locked compressor. 9. Repair or replace compressor.
10. Icing. 10. Check for suction line frosting.
Replace expansion valve if
necessary.
Replace receiver/drier if necessary.
D.1. Motor and/or blades improperly 1. Check mountings, adjust as
CONDENSERmounted. necessary.
VIBRATION2. Foreign matter build-up on 2. Clean blades with a suitable
blades. non-inflammable cleaner.
3. Excessive wear of motor bearings. 3. Replace motor.

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 wrench
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 desiccant 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
Unipart R134a ND-OIL8
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..........................................................
Evaporator 80ml..........................................................
Pipe or hose 20ml........................................................
Receiver/drier 20ml......................................................
Total of 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 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
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) = 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 discharged
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 the following amount
of new refrigerant oil:
130ml
3.Plug the inlet and outlet ports.

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
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Air conditioning
Compressor flange bolts 10............................................................................
Receiver drier union bolts 6...........................................................................
Dual pressure switch 11..................................................................................
Pressure pipe union nuts - M16 14.................................................................
Discharge pipe union nuts - M22 22...............................................................
Suction pipe union nuts - M24 33...................................................................
AIR CONDITIONING CHARGE DATA
Total oil in system 180ml - 6.3Fl oz...........................................................................
Total refrigerant in system 0,90kg - 32Fl oz..............................................................
Total refrigerant in system with rear air conditioning 1,15kg - 40Fl oz.......................

ELECTRICAL
25
REPAIR STARTER MOTOR - Mpi
Service repair no - 86.60.01
Remove
1.Disconnect battery negative lead.
2.Remove 2 nuts securing cables to starter
solenoid; release cables.
3.Remove 3 bolts securing starter motor.
4.Manoeuvre starter motor clear of bell housing.
5.Remove starter motor.Refit
6.Clean mating faces of starter motor and
differential housing.
7.Manoeuvre starter motor into position.
8.Fit mounting bolts and Tighten to
45 Nm.
9.Connect battery cables to starter solenoid; fit
nuts and tighten to the correct torque.
10.Reconnect battery negative lead.

ELECTRICAL
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Generator
Generator mounting bracket to cylinder head 34............................................
Generator to mounting bracket 24..................................................................
Generator shaft nut 35....................................................................................
Generator through bolts 5..............................................................................
Generator rectifier bolts 3,5.............................................................................
Amplifier module screws 1,2............................................................................
Amplifier heat sink screws 1,2.........................................................................
Auxiliary driving lamp mounting bolts 15.........................................................
Distributor clampbolt 20..................................................................................
Distributor pick-up bearing plate support pillars 1,2.........................................
Distributor pick-up barrel nuts 1,2....................................................................
Distributor vacuum unit 2...............................................................................
Torque values below cover all screws and bolts used, unless specified otherwise.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................