cooling LAND ROVER DISCOVERY 2002 Workshop Manual

AIR CONDITIONING
82-4DESCRIPTION AND OPERATION
Refrigerant system
Schematic of air conditioning system
1Evaporator
2Thermostatic expansion valve
3Low pressure servicing connection
4Outlet to rear A/C system (where fitted)
5Dual pressure switch
6Receiver drier
7Cooling fan
8Condenser
9Compressor10Inlet from rear A/C system (where fitted)
11High pressure servicing connection
12Air flows
aAmbient air
bCooled air
cAmbient air through condenser
13Refrigerant
aLiquid
bVapour
The refrigerant system transfers heat from the vehicle interior to the outside atmosphere to provide the heater
assembly with dehumidified cool air. The system comprises a compressor, condenser, receiver drier, thermostatic
expansion valve and evaporator, joined together by refrigerant lines. The system is a sealed, closed loop, filled with
a charge weight of R134a refrigerant as the heat transfer medium. Oil is added to the refrigerant to lubricate the
internal components of the compressor.

AIR CONDITIONING
82-6DESCRIPTION AND OPERATION
Condenser
1Condenser matrix
2Outlet connection
3Inlet connection
The condenser transfers heat from the refrigerant to the surrounding air.
The condenser is installed immediately in front of the oil coolers. Rubber mounting bushes are used to mount the
condenser to the chassis sidemembers and brackets on the headlamp panels.
Ambient air, passing through the condenser matrix due to ram effect and/or the cooling fan, absorbs heat from the
refrigerant, which changes state from a vapour to a liquid.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-13
3 Hand of drive Input
4 Distribution flaps position Input
5 Heater coolant temperature Input
6 External air temperature Input
7 In-car air temperature Input
8 Blower power transistor collector voltage Input
9 Not used-
10 Not used-
11 Windscreen heater status Input
12 Rear screen heater status Input
13 Not connected -
14 Driver's blend flaps position Input
15 Passenger's blend flaps position Input
16 LH solar heating load Input
17 RH solar heating load Input
18 Evaporator Input
19 Not used-
20 Not used-
C0793
1 Blower power transistor base current Output
2 Blower relay Output
3 Windscreen heater request Output
4 Rear screen heater request Output
5 Passenger's blend flaps servo motor, drive to hot Output
6 Driver's blend flaps servo motor, drive to hot Output
7 Distribution flaps servo motor, drive to windscreen and side
windows demistOutput
8 Fresh/Recirculated air servo motor, drive to recirculated air Output
9 Cooling fan request (diesel models) Output
10 Power relay Output
11 Compressor clutch request Output
12 Cooling fan request (V8 models) Output
13 Passenger's blend flaps servo motor, drive to cold Output
14 Driver's blend flaps servo motor, drive to cold Output
15 Distribution flaps servo motor, drive to footwells Output
16 Fresh/Recirculated air servo motor, drive to fresh air Output Connector/Pin No. Description Input/Output

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-17
RH temperature. Illuminates to show the RH temperature selection, external air temperature or diagnostic fault code.
Blower speed. Illuminates when the blower speed is manually selected. Also illuminates in the automatic modes when
one of the temperatures is set to LO or HI.
External air temperature. EXT illuminates to show that external air temperature is selected on.
All temperature indications on the display are in either
°C or °F. For 1 second after the system is first switched on, the
display shows only
°C or °F, in the LH temperature window, to indicate which temperature scale is in use. After 1
second, the
°C or °F indication goes off and the display shows all relevant outputs.
Temperature conversion: While the system is on, the temperature indications on the display can be switched between
the two scales by pressing and holding the fresh/recirculated air switch, then pressing and holding the A/C on/off
switch until the audible warning sounds (approximately 3 seconds).
Dual pressure switch
The dual pressure switch protects the refrigerant system from extremes of pressure. The normally closed switch is
installed in the top of the receiver drier. If minimum or maximum pressure limits are exceeded the switch contacts
open, causing the compressor clutch to be disengaged. The minimum pressure limit protects the compressor, by
preventing operation of the system unless there is a minimum refrigerant pressure (and thus refrigerant and
lubricating oil) in the system. The maximum pressure limit keeps the refrigerant system within a safe operating
pressure.
Dual pressure switch nominal operating pressures
Evaporator temperature sensor
The evaporator temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of the
evaporator air outlet temperature. The evaporator temperature sensor is installed in a clip which locates in the
evaporator matrix in the heater assembly. The ATC ECU uses the input to prevent the formation of ice on the
evaporator.
In-car temperature sensor
The in-car temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of cabin air
temperature. The sensor is integrated into the inlet of an electric fan, which is installed behind a grille in the fascia
outboard of the steering column. The fan runs continuously, while the ignition is on, to draw air through the grille and
across the sensor.
Sunlight sensor
The sunlight sensor consists of two diodes that provide the ATC ECU with inputs of light intensity, one as sensed
coming from the left of the vehicle and one as sensed coming from the right. The inputs are used as a measure of the
solar heating effect on vehicle occupants. The sensor is installed in the centre of the fascia upper surface.
Heater coolant temperature sensor
The heater coolant temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input related
to heater matrix coolant temperature. The sensor is installed in the casing of the heater assembly and presses against
the end tank of the heater matrix.
Ambient temperature sensor
The ambient temperature sensor is an encapsulated thermistor that provides the ATC ECU with an input of external
air temperature. The sensor is attached to the cooling fan mounting bracket in front of the condenser.
Limit Opening pressure, bar (lbf.in2) Closing pressure, bar (lbf.in2)
Minimum 2.0 (29.0), pressure decreasing 2.3 (33.4), pressure increasing
Maximum 32 (464), pressure increasing 26 (377), pressure decreasing

AIR CONDITIONING
82-18DESCRIPTION AND OPERATION
Operation
General
While the system is on, the ATC ECU operates the refrigerant system and the inlet air, blower speed, air temperature
and air distribution functions to produce the conditions requested on the control panel. When the system is first
switched on, the ATC ECU resumes the control outputs in use when the system was last switched off. If conditions
have changed, or a different mode is selected to switch the system on, the control outputs are then changed to
produce the required new settings.
The system operates in automatic, economy and defrost modes, with manual overrides of the inlet air source, blower
speed and air distribution. The air temperature is automatically controlled in all operating modes.
In the automatic mode, the ATC ECU operates the system to warm-up or cool down the cabin to establish and
maintain the temperature selections on the control panel, while directing the air to those outlets most comfortable for
the occupant(s). If a difference between the LH and RH temperature selections causes a conflict of the required inlet
air source, blower speed or air distribution settings, priority is given to achieving the temperature requested on the
driver's side of the control panel.
The ATC ECU enters the economy mode when the refrigerant compressor is selected off while the system is in the
automatic mode, which reduces the load on the engine. Economy mode operation is similar to the automatic mode,
but without the ability to cool the cabin if the ambient temperature is higher than the temperature selections made on
the control panel, or to dehumidify the air in the cabin.
In the defrost mode, the ATC ECU sets the inlet air source to fresh air, the blower to maximum speed, the air
distribution to windscreen and side windows, and outputs signals to the BCU to operate the rear window heater and
(where fitted) the windscreen heater. The BCU starts or, if the heaters are already on, resets the heater timers and
energises the rear window and windscreen heaters for a complete on cycle.
Air temperature control
To determine the amount of heat or cooling required by the cabin, the ATC ECU uses the sensor inputs and the
temperatures selected on the control panel to calculate target air outlet temperatures for the driver's and the front
passenger's side of the heater assembly. The ATC ECU then signals the servo motors controlling the respective blend
flaps in the heater assembly to move to the flaps to the appropriate position. The target temperatures are constantly
updated and, in the automatic mode, also used in further calculations to determine the inlet air source, the blower
speed and the air distribution.
Inlet air control
The inlet air source is automatically controlled while the system is off or on. While the system is on, the inlet air source
can also be manually controlled to give timed recirculated air or latched recirculated air.
While the system is off, the ATC ECU uses vehicle speed to determine the inlet air source. With the vehicle at rest,
the inlet air source is set to recirculated air. When vehicle speed reaches 17.5 mph (28 km/h), the inlet air source
changes to fresh air. The inlet air source then remains at fresh air until the vehicle speed decreases to 5 mph (8 km/
h), when it returns to recirculated air.
While the system is on, the ATC ECU uses the LH and RH temperature selections, vehicle speed, ambient air
temperature and coolant temperature to determine the inlet air source. In the automatic mode:
lIf one temperature selection is set to LO and one is set to a specific temperature or HI, the inlet air is set to
recirculated air.
lIf one temperature selection is set to HI and one is set to a specific temperature or HI, the inlet air is set to fresh
air.
lWhen specific LH and RH temperature selections are set, the inlet air source remains at fresh air except when
the air distribution function is set to face level only or face level and footwell outlets. If the air distribution function
is set to face level only or face level and footwell outlets, at 56 mph (90 km/h) the inlet air source changes to
recirculated air (to exclude ram effect, which becomes excessive at speed). When the vehicle speed decreases
to 37.5 mph (60 km/h), the inlet air source returns to fresh air.

AIR CONDITIONING
82-20DESCRIPTION AND OPERATION
Air distribution control
To control the air distribution within the cabin the ATC ECU signals the servo motor controlling the distribution flaps
in the heater assembly to move to the flaps to the appropriate position.
In the automatic and economy modes, if the LH or RH temperature selections are set to LO or HI, air distribution is
fixed as follows:
lIf one is set to LO and one is set to a specific temperature, to face level only.
lIf one is set to HI and one is set to a specific temperature, to footwells only.
lIf one is set to LO and one is set to HI, to face level and footwells.
When specific LH and RH temperature selections are set, air distribution is determined from the target air outlet
temperatures. For higher target air outlet temperatures, air distribution is set to footwells only. For lower target air
outlet temperatures, air distribution is set to face level only. For intermediate target air outlet temperatures, air
distribution is set to face level and footwells. When the air distribution is set to face level and footwells, the ATC ECU
varies the bias between the footwells and the face level outlets, in three stages, to provide a gradual transition of air
distribution from footwells only to face level only. The three stages of bias are also employed when the air distribution
is manually selected to face level and footwells.
During warm-up, the air distribution changes to face level and footwells for a period, then reverts to footwells only.
The period of air distribution at face level and footwells can be cancelled by pressing and holding the on/off and defrost
mode switches, then turning the ignition switch from off to on. Pressing and holding the AUTO and defrost switches,
then turning the ignition switch from off to on, restores the period of air distribution at face level and footwells.
Compressor control
To engage the compressor clutch, the ATC ECU outputs a compressor clutch request to the ECM, which then
energises the A/C compressor clutch relay. Compressor operation is governed by the evaporator outlet air
temperature, at one of two settings, dependent on the amount of cooling required. When more cooling is required, the
compressor clutch request is output if evaporator outlet air temperature increases to 4
°C (39 °F) and cancelled when
it decreases to 3
°C (37 °F). When less cooling is required, the compressor clutch request is output if evaporator outlet
air temperature increases to 11
°C (52 °F) and cancelled when it decreases to 10 °C (50 °F).
Engine cooling fan control
While the A/C system is on, operation of the electric engine cooling fan, to assist refrigerant condenser operation, is
determined by a combination of vehicle speed and external air temperature. When cooling fan operation is required,
the ATC ECU outputs a cooling fan request to the ECM, which then energises the cooling fan relay. The cooling fan
request is output if vehicle speed is 80 km/h or less while the external air temperature is 28
°C (82 °F) or more. The
request is cancelled, and the cooling fan switched off, if either the vehicle speed increases to 100 km/h, or the external
air temperature decreases to 25
°C (77 °F).
Default settings
If the battery power supply to the ATC ECU is disrupted for any reason, e.g. battery disconnected, the system reverts
to default settings when the battery power supply is restored. Default settings are:
lTemperature indications in
°C (in some markets a conversion connector is fitted to the ATC ECU to change the
default temperature scale to
°F).
lLH and RH outlet temperatures of 22
°C (72 °F).
laudible warning switched on.
lWarm-up air distribution (to face level and footwells) function switched on.
lIf the system is first switched on using the A/C on/off switch, the automatic mode is engaged, regardless of the
settings in use when the battery was disconnected.

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-21
Diagnostics
The ATC ECU performs a diagnostic check each time the ignition is switched on. To avoid nuisance fault indications
at low light levels, the sunlight sensor is omitted from the diagnostic check. If a fault is detected, the audible warning
sounds three times and the AUTO window on the control panel display flashes for 20 seconds. The ATC ECU then
reverts to normal control but uses a default value or strategy for the detected fault. Faults are identified by performing
a manual diagnostic check of the system.
A manual diagnostic check includes a check of the sunlight sensor, and is initiated by pressing and holding the AUTO
switch and the air distribution switch, then turning the ignition switch from off to on. The audible warning sounds once
and the indications on the control panel display illuminate. FC is shown in the LH temperature window and the results
of the check are shown as a two digit fault code in the RH temperature window. If a fault is detected, the audible
warning sounds three times and the AUTO window on the display flashes on and off for 20 seconds. If more than one
fault is detected, the fault codes cycle in numerical order, at 1 Hz. The audible warning sounds as each fault code is
shown. In low light conditions, to avoid false sunlight sensor fault indications, the sunlight sensor should be illuminated
with a strong light source.
Diagnostic fault codes and fault descriptions
Code Component Fault Default value/strategy
00 - No fault found -
11 In-car temperature sensor Open or short circuit 25°C (77°F)
12 Ambient temperature sensor Open or short circuit 10°C (50°F)
Cooling fan permanently on
Display shows "- -" if external
air temperature selected
13 Thermistor Open or short circuit 0°C (32°F)
14 Heater coolant temperature sensor Open or short circuit 70°C (158°F)
21 Sunlight sensor, left output Open or short circuit No solar heating correction
22 Sunlight sensor, right output Open or short circuit No solar heating correction
31 LH temperature servo motor Open or short circuit
Motor or flap mechanism seizedServo motor locked in position
32 RH temperature servo motor Open or short circuit
Motor or flap mechanism seizedServo motor locked in position
33 Distribution servo motor Open or short circuit
Motor or flap mechanism seizedServo motor locked in position

AIR CONDITIONING
REPAIRS 82-31
REPAIRS
Compressor - diesel
$% 82.10.20
Remove
1.Remove engine acoustic cover.
2.Depressurise air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
4.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
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
1.Calculate the quantity of refrigerant oil required.

+ GENERAL INFORMATION, Air
Conditioning Compressor Replacement.
2.Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
3.Remove caps from compressor and pipe
connections.
4.Clean compressor and pipe connections.
5.Lubricate new 'O'rings with refrigerant oil and
fit to compressor.
6.Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft) .
7.Connect multiplug to compressor.
8.Position top hose and secure with clips.
9.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
10.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
11.Recharge air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
12.Fit engine acoustic cover.

AIR CONDITIONING
REPAIRS 82-33
Fan - condenser
$% 82.15.01
Remove
1.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
2.Remove 2 bolts securing bonnet platform RH
support stay.
3.Remove support stay.
4.Disconnect multiplug from condenser cooling
fan motor.
5.Remove 4 screws securing cooling fan cowl to
mounting bracket.
6.Remove cooling fan assembly and collect
spacing washers.
Refit
1.Fit condenser fan.
2.Fit spacing washers between fan cowl and
mounting bracket and secure with screws.
3.Connect multiplug to motor.
4.Fit bonnet platform support stay and secure
with bolts.
5.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
Condenser
$% 82.15.07
Remove
1.Recover refrigerant from A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Remove radiator.
l

+ COOLING SYSTEM - Td5,
REPAIRS, Radiator.
l

+ COOLING SYSTEM - V8,
REPAIRS, Radiator.
3.Disconnect multiplug from dual pressure
switch.
4.Remove bolt securing evaporator pipe to
condenser.
5.Disconnect evaporator pipe from condenser
and discard 'O' ring.
6.Remove bolt securing evaporator pipe to
receiver drier.
7.Disconnect evaporator pipe from receiver drier
and discard 'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.

AIR CONDITIONING
82-34REPAIRS
8.Remove 3 remaining bolts securing cooling fan
support rails to condenser.
9.Remove condenser.
10.Remove bolt securing adaptor block to receiver
drier.
11.Remove adaptor block from receiver drier and
discard 'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.12.Remove bolt securing condenser pipe to
receiver drier.
13.Remove clamp bolt receiver drier to bracket
and remove drier from bracket.
14.Remove and discard 'O' ring from condenser
pipe.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15.Remove 2 remaining bolts securing receiver
drier brackets and condenser LH mounting
bracket to condenser.
16.Remove mounting bracket assembly.
17.Remove remaining bolt securing condenser RH
mounting and remove mounting.