service LAND ROVER DISCOVERY 1995 Workshop Manual

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.

AIR CONDITIONING
13
REPAIR BLOWER MOTOR - REAR
Service repair no - 82.26.02
Remove
1.Remove evaporator/blower motor assembly.
See evaporator/blower motor assembly -
rear
2.Loosen 2 screws securing high pressure control
valve solenoid to blower motor housing.
3.Disconnect multiplug from blower motor.
4.Release blower motor cooling tube from
evaporator/blower motor housing.
5.Remove 3 screws securing blower motor.
6.Remove blower motor .
Refit
7.Position blower motor to housing and secure
with screws.
8.Secure blower motor cooling tube from
evaporator/blower motor housing.
9.Connect multiplug to blower motor.
10.Tighten screws securing control valve solenoid.
11.Fit evaporator/blower motor assembly.
See
evaporator/blower motor assembly - rear;
Refit
ELECTRONIC CONTROL UNIT - REAR AIR
CONDITIONING
Service repair no - 82.26.03
Remove
1.Remove rear compartment lower trim panel.
See CHASSIS AND BODY, Repair, rear
compartment lower trim panel - lh - with rear
air conditioning fitted
2.Disconnect multiplug from ECU.
3.Remove ECU from mounting bracket.
Refit
4.Fit ECU to mounting bracket and connect
multiplug.
5.Fit rear compartment lower trim panel.
See
CHASSIS AND BODY, Repair, rear
compartment lower trim panel - lh - with rear
air conditioning fitted; Refit

82AIR CONDITIONING
14
REPAIR SOLENOID - HIGH PRESSURE PIPE CONTROL
VALVE - REAR
Service repair no - 82.26.05
Remove
1.Remove evaporator/blower motor assembly.
See evaporator/blower motor assembly -
rear
2.Release multiplug clip from solenoid bracket.
3.Disconnect solenoid multiplug.
4.Loosen 2 control valve unions.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
5.Remove 2 screws securing control valve to
blower motor housing.
6.Release unions from control valve.
7.Remove and discard 2 'O' ring seals from control
valve.
CAUTION: Immediately plug air
conditioning connections.
8.Remove control valve assembly.
9.Remove 2 screws securing mounting bracket to
control valve.
10.Remove mounting bracket.
11.Noting the direction arrow on control valve,
remove screw securing solenoid to valve.
12.Remove solenoid from valve.

AIR CONDITIONING
15
REPAIR Refit
13.Fit solenoid to valve.
14.Fit but do not tighten screw securing solenoid to
control valve.
NOTE: Ensure arrow on control valve is
pointing in the correct recorded direction.
15.Position mounting bracket to control valve
solenoid and secure with screws.
16.Remove plugs from unions and control valve
connections.
17.Lubricate NEW 'O' rings with refrigerant oil and
fit to valve.
18.Fit control valve to pipes, connect unions, but do
not tighten.
19.Fit and tighten screws securing control valve
mounting bracket to blower motor housing.
20.Tighten control valve unions to
14 Nm.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
21.Tighten screw securing solenoid to control valve.
22.Connect solenoid multiplug and secure to
solenoid bracket.
23.Fit evaporator/blower motor assembly.
See
evaporator/blower motor assembly - rear;
Refit
CONTROL VALVE - HIGH PRESSURE PIPE - REAR
Service repair no - 82.26.05
Remove
1.Remove evaporator/blower motor assembly.
See evaporator/blower motor assembly -
rear
2.Release multiplug clip from solenoid bracket.
3.Disconnect solenoid multiplug.
4.Loosen 2 control valve unions.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
5.Remove 2 screws securing control valve to
blower motor housing.
6.Release unions from control valve.
7.Remove and discard 2 'O' ring seals from control
valve.
CAUTION: Immediately plug air
conditioning connections.
8.Remove control valve assembly.

AIR CONDITIONING
17
REPAIR EXPANSION VALVE - REAR
Service repair no - 82.26.07
Remove
1.Remove evaporator/blower motor assembly.
See evaporator/blower motor assembly -
rear
2.Remove foam insulation from expansion valve
and expansion valve probe.
3.Remove expansion valve probe retaining clip.
4.Loosen expansion valve unions.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
5.Remove and discard 'O' rings from evaporator
and air conditioning pipes.
6.Plug expansion valve and connections.
7.Remove expansion valve.Refit
8.Position expansion valve probe to evaporator
pipe and secure with clip.
9.Remove plugs from expansion valve and
connections.
10.Lubricate NEW 'O' rings and fit to pipes.
11.Position expansion valve to pressure pipe and
tighten union to
14 Nm.
12.Position expansion valve to evaporator pipe and
tighten union to
22 Nm.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
13.Remove backing paper from NEW foam
insulation.
14.Fit foam insulation to expansion valve and
expansion valve probe.
15.Fit evaporator/blower motor assembly.
See
evaporator/blower motor assembly - rear;
Refit

82AIR CONDITIONING
18
REPAIR EVAPORATOR - REAR
Service repair no - 82.26.08
Remove
1.Remove evaporator/blower motor assembly
harness.
See harness - evaporator/blower
motor assembly - rear
2.Remove foam seal from evaporator to alpine
light duct flange.
3.Remove screw securing air conditioning
pressure pipe 'P' clip to casing.
4.Remove 4 screws securing evaporator/blower
motor lower casing.
5.Remove lower casing.
6.Remove foam insulation from expansion valve
and expansion valve probe.
7.Loosen expansion valve to evaporator union.
CAUTION: Use 2 spanners when loosening
or tightening air conditioning pipe unions.
8.Remove and discard 'O' ring from evaporator
pipe.
9.Plug expansion valve to evaporator connections.
10.Remove expansion valve probe retaining clip.

82AIR CONDITIONING
20
REPAIR THERMOSTAT - REAR
Service repair no - 82.26.09
Remove
1.Remove evaporator/blower motor assembly
harness.
See harness - evaporator/blower
motor assembly - rear
2.Remove foam seal from evaporator to alpine
light duct flange.
3.Remove screws securing 2 relay mounting
brackets to evaporator/blower motor casing and
position aside.
4.Disconnect 2 Lucars from thermostat.
5.Loosen 2 screws securing thermostat.
6.Release thermostat from bracket.
7.Remove 2 clips securing evaporator/blower
motor casing halves.
8.Remove screw securing evaporator/blower
motor casing halves.
9.Separate casing sufficiently to enable removal of
thermostat probe from casing.
10.Remove thermostat.
Refit
11.Position thermostat fixings to casing and tighten
screws.
12.Connect Lucars to thermostat.
13.Separate casing sufficiently to enable fitment of
thermostat probe to casing.
14.Fit and tighten screw securing casing halves.
15.Fit clips securing casing halves.
16.Remove backing paper from NEW foam,
evaporator to alpine light duct, flange seal.
17.Fit foam seal to evaporator/blower motor casing
flange.
18.Fit evaporator/blower motor assembly harness.
See harness - evaporator/blower motor
assembly - rear; Refit

AIR CONDITIONING
21
REPAIR HARNESS - EVAPORATOR/BLOWER MOTOR
ASSEMBLY - REAR
Service repair no - 82.26.12
Remove
1.Remove evaporator/blower motor assembly.
See evaporator/blower motor assembly -
rear
2.Remove screw securing harness retaining clip to
casing.
3.Release harness clip from casing tag.
4.Disconnect 4 relay multiplugs.
5.Disconnect 2 Lucars from thermostat.
6.Disconnect multiplug from ECU.
7.Release control valve solenoid multiplug from
mounting bracket and disconnect multiplug.
8.Disconnect multiplug from blower motor.
9.Disconnect multiplug from resistor.
10.Remove harness.Refit
11.Fit harness and route into position.
12.Connect multiplug to resistor.
13.Connect multiplug to blower motor.
14.Connect control valve solenoid multiplug and
secure multiplug to mounting bracket.
15.Connect multiplug to ECU.
16.Connect Lucars to thermostat.
17.Connect multiplugs to relays.
18.Secure harness clip to casing tag.
19.Fit screw securing harness retaining clip to
casing.
20.Fit evaporator/blower motor assembly.
See
evaporator/blower motor assembly - rear;
Refit

82AIR CONDITIONING
22
REPAIR REAR AIR CONDITIONING SWITCH
Service repair no - 82.26.14
Remove
1.Open rear door.
2.Release switch pack from headlining panel.
3.Disconnect 2 multiplugs and 2 Lucars from
switch pack.
4.Remove switch pack assembly.
5.Remove blower motor control knob.
6.Release 3 tags securing switch pack display
panel and remove panel.
7.Remove switch from switch pack.
Refit
8.Fit switch to switch pack.
9.Fit display panel and secure to tags.
10.Fit blower motor control knob.
11.Position switch pack assembly, connect
multiplugs and Lucars and secure to headlining
panel.
12.Close rear door.