charging LAND ROVER DISCOVERY 2002 Repair Manual

AIR CONDITIONING
DESCRIPTION AND OPERATION 82-9
Evaporator
The evaporator is installed in the air inlet of the heater assembly and absorbs heat from the exterior or recirculated
inlet air. Low pressure, low temperature refrigerant changes from liquid to vapour in the evaporator, absorbing large
quantities of heat as it changes state.
Refrigerant lines
To maintain similar flow velocities around the system, the diameter of the refrigerant lines varies to suit the two
pressure/temperature regimes. The larger diameters are installed in the low pressure/temperature regime and the
smaller diameters are installed in the high pressure/temperature regime. Low and high pressure charging connections
are incorporated into the refrigerant lines for system servicing. Where rear AC is installed, connections for the rear
refrigerant lines are incorporated next to the charging connections.

AIR CONDITIONING
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 82-29
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
Refrigerant recovery, recycling and
recharging
$% 82.30.02
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.
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.
WARNING: Refrigerant must always be
recycled before re-use to ensure that the
purity of the refrigerant is high enough for
safe use in 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
recycle refrigerant to the required level of
purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with
any other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in
motor vehicle air conditioning systems.
8.Close valves on refrigerant station.
9.Turn Main switch to 'OFF'.
10.Close valves on connectors.
11.Disconnect connectors high and low pressure
hoses from connectors.
12.Fit dust caps to connectors. 13.Open tap at rear of station to drain refrigerant
oil.
14.Measure and record quantity of refrigerant oil
recovered from system.
15.Close tap at rear of station.
Evacuation
WARNING: Servicing must only be carried
out by personnel familiar with both the
vehicle system and the charging and testing
equipment. All operations must be carried
out in a well ventilated area away from open
flame and heat sources.
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.
Recharging
NOTE: When recharging, always make
allowance for refrigerant in the line between the
charging station and the vehicle. This is
calculated at 30 grammes/metre of charging
line. System charge weights are 700
± 25
grammes for front A/C system only and 900
±
25 grammes for combined front and rear A/C
system.
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 same quantity of refrigerant oil into oil
charger as collected during recovery. If the
following components have been renewed, add
the following additional quantity of lubricating
oil:
lCondenser = 40 cm
3
lEvaporator = 40 cm3
lPipe or hose = 5 cm3/metre
lReceiver/dryer = 15 cm3.
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 charge quantity.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Capacities.

AIR CONDITIONING
82-30REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
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.Turn Main switch to 'OFF'.
13.Close valves on connectors.
14.Disconnect high and low pressure hoses from
connectors.
15.Fit dust caps to connectors.

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
82-32REPAIRS
Compressor - V8
$% 82.10.20
Remove
1.Depressurise air conditioning system.

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

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
3.Disconnect multiplug from compressor.
4.Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 4 bolts securing compressor to
mounting bracket.
6.Remove compressor.Refit
1.Calculate the quantity of refrigerant oil required.

+ GENERAL INFORMATION, Air
Conditioning Compressor Replacement.
2.Clean compressor dowels and dowel holes.
3.Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
4.Remove caps from compressor and pipe
connections.
5.Clean compressor and pipe connections.
6.Lubricate new 'O' rings with refrigerant oil and
fit to compressor.
7.Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft).
8.Connect multiplug to compressor.
9.Fit auxiliary drive belt.

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

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

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
REPAIRS 82-35
18.Remove sealing strip from outer upper seam of
condenser.
19.Remove captive nut plates from condenser.
Refit
1.Fit captive nut plates to new condenser.
2.Fit seal to condenser.
3.Fit RH mounting bracket to condenser and
secure with bolt.
4.Fit receiver drier bracket assembly and secure
with bolts.
5.Ensure condenser pipe and new receiver drier
connections are clean.
6.Lubricate new 'O' ring with refrigerant oil and fit
to condenser pipe.
7.Fit receiver drier to bracket and condenser
pipe. Tighten bolt securing condenser pipe to 5
Nm (3.7 lbf.ft). Fit clamping bolt securing
receiver drier to bracket and tighten to 5 Nm
(3.7 lbf.ft).
8.Ensure adaptor block and receiver drier
connections are clean.
9.Lubricate new 'O' ring with refrigerant oil and fit
to adaptor block.
10.Fit adaptor block to receiver drier and tighten
bolt to 5 Nm. (3.7 lbf.ft).
11.Fit condenser assembly. 12.Fit cooling fan to condenser and fit bolts to
secure support rails to condenser brackets.
13.Ensure connections of condenser, receiver
drier and evaporator pipes are clean.
14.Lubricate new 'O' ring seals with refrigerant oil
and fit one seal to each evaporator pipe.
15.Connect evaporator pipes and tighten bolts to 5
Nm (3.7 lbf.ft).
16.Connect multiplug to dual pressure switch.
17.Fit radiator.
l

+ COOLING SYSTEM - Td5,
REPAIRS, Radiator.
l

+ COOLING SYSTEM - V8,
REPAIRS, Radiator.
18.Recharge A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.

AIR CONDITIONING
82-36REPAIRS
Receiver drier and dual pressure switch
$% 82.17.03
Remove
1.Recover refrigerant from air conditioning
system.

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

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
3.Disconnect multiplug from dual pressure
switch.
4.Remove bolt securing condenser pipe to
receiver drier.
5.Disconnect condenser pipe from receiver drier.
CAUTION: Always fit plugs to open
connections to prevent contamination.6.Remove bolt securing evaporator pipe to
receiver drier.
7.Disconnect evaporator pipe from receiver
drier.
CAUTION: Always fit plugs to open
connections to prevent contamination.
8.Remove bolt securing top of receiver drier
mounting bracket to condenser.
9.Remove bolt securing bottom of receiver drier
mounting bracket to condenser.
10.Remove receiver drier assembly.
11.Loosen mounting bracket clamping bolt.

AIR CONDITIONING
REPAIRS 82-37
12.Remove receiver drier from mounting bracket.
13.Remove dual pressure switch from receiver
drier
Refit
1.Fit dual pressure switch to receiver drier and
tighten to 10 Nm (7 lbf.ft).
2.Fit receiver drier to mounting bracket and
tighten clamping bolt.
3.Fit receiver drier assembly to condenser.
4.Fit bolts securing receiver drier mounting
bracket to condenser and tighten to 5 Nm (3.7
lbf.ft).
5.Remove caps from air conditioning pipes and
receiver drier.
6.Remove old 'O' rings from pipes.
7.Fit new 'O' rings to pipes and lubricate with
refrigerant oil.
8.Connect air conditioning pipes to receiver
drier.
9.Fit bolts securing air conditioning pipes to
receiver drier and tighten to 5 Nm (3.7 lbf.ft).
10.Connect multiplug to dual pressure switch.
11.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
12.Recharge air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
ECU - air temperature control
$% 82.20.90
Remove
1.Release radio from fascia.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio cassette player.
2.Working through radio aperture, release control
unit from fascia.
3.Disconnect 3 multiplugs and remove control
unit.
4.Collect bushes from control unit location pegs.
Refit
1.Fit bushes to new control unit.
2.Position control unit and connect multiplugs.
3.Fit control unit to fascia.
4.Fit radio to fascia.

+ IN CAR ENTERTAINMENT,
REPAIRS, Radio cassette player.

AIR CONDITIONING
82-42REPAIRS
13.Remove covering from TX valve, release 2
clips securing TX valve to pipe.
14.Release 2 unions securing TX valve, remove
TX valve, remove and discard 'O' rings.
15.Release pipe union, remove pipe and discard
'O' ring.
Refit
1.Using a new 'O' ring, position pipe to
evaporator and tighten union.
2.Using new 'O' rings, position TX valve. Connect
pressure pipe union and tighten to 22 Nm (16
lbf. ft). Connect evaporator pipe and tighten to
32 Nm (24 lbf.ft).
3.Position TX valve sensor to pipe and secure
with clips.
4.Fit sensor covering.
5.Fit evaporator thermistor.
6.Fit evaporator assembly.
7.Fit insulation to evaporator casing and fit
casing.
8.Secure spring clips.
9.Fit and tighten casing screws.
10.Fit heater matrix, ensuring matrix temperature
is correctly positioned.
11.Fit coolant pipe saddle, fit and tighten screws
securing saddle and pipe bracket.
12.Fit and tighten temperature servo screws.
13.Connect multiplug to evaporator thermistor.
14.Clean any bulk head seal from casing.
15.Fit bulkhead and evaporator pipe seals.
16.Fit heater assembly.

+ HEATING AND VENTILATION,
REPAIRS, Heater assembly - models with
air conditioning.
Expansion valve - (TXV) - rear
$% 82.26.01
Remove
1.Depressurise air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Remove rear lower trim casing.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
3.Remove 5 bolts securing seat support bracket
and remove bracket.
4.Release insulation from TXV pipe unions and
sensor.
5.Remove clip securing sensor to pipe and
release sensor.