Land Rover 90 110 Workshop Rover Manual
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AIR CONDITIONING- L.H. & R.H. STEERING 1821 COMPRESSOR Petrol model Removal , .I /:. . ./. m 1. Place the vehiclc in a ventilated area away from open flames and heat sources. 2. Stop the engine and secure the bonnet in an open position. 3. Remove the caps from the compressor service valves and connect the gauge set for evacuating. 4. Evacuate the system as previously described. 5. Open fully (turn anti-clockwise) the compressor service valves and disconnect the gauge set. Cap all pipe and valve connections to prevent dirt or moisture entering the system. 6. Remove the electrical connections to the compressor. -. V8 models only 4 -cylinder Petrol only 9. Release the jockey wheel adjuster to enable the 10. Release the tensioner on the compressor drive belt. 11. Remove the fixing bolt and swivel the compressor and bracket assembly to expose the bolt which is securing the bracket. 12. Remove the bolt and lift the compressor and bracket clear and place on a bench. 13. Whilst supporting the compressor, remove the five bolts holding the compressor to the brackets. front drive (fan) belt to be removed. 7. Shckcn all the ComPressor adjustment fixin@ and 8. Remove the adjusting and pivot fixings and the remove the drive belt from the compressor. compressor from retaining bracket. Diesel model 8- ST1418M All engines 14. No servicing is recommended to the compressor, therefore a new unit must be fitted. 15. Reverse procedure as appropriate 13 to 9 and 6 to 3 for V8 models or 8 to 3 for 4-cylinder models noting the procedure for adjusting the compressor drive belts. 17
El AIR CONDITIONING - L.H. & R.H. STEERING Refitting Drive belt adjustment Diesel only 16. Ensure all adjustment bolts associated with the compressor are slack. 17. Alter the position of the compressor to provide a belt tension of 4 -6 mm (0.19-0.25 in). Secure all compressor adjustment bolts and recheck the tension. 4-cylinder Petrol only 18. Ensure all adjustment bolts associated with the compressor (1) and the lower pulley pivot fixing (2) are slack. 19. Adjust the position of the lower pulley to give a belt tension of 4-6 mm (0.19-0.25 in). 20. Tighten the pivot bolt and recheck the tension. 21. Alter the position of the compressor to provide a 22. Secure all compressor adjustment bolts and belt tension of 4-6 mm (0.19-0.25 in). recheck the tension. 1 ST1409M 24. Alter the position of the compressor to provide a belt tension of 4-6 mm (0.19-0.25 in). Secure all compressor adjustment bolts and recheck the tension. 25. Ensure the jockey pulley adjustment bolts are slack. 26. Alter the position of the jockey pulley to give a belt tension of 4-6 mm (0.19-0.25 in). Secure the adjustment bolts and recheck tension. ST1391 M ST 1401M CONDENSER FAN MOTORS Removal 1. Open and secure the bonnet. 2. Release the six self tapping screws securing the front nose and grille assembly, lift clear. 3. Disconnect the electrical leads to the fans. 4. Remove the blanking caps from the fan centres. 5. Remove the 8 mm securing nuts, star and spring washers from the fan blade centres, pull blade from its respective fan motor shaft. 6. Release the two fan motor retaining bolts and remove the motor whilst feeding the fan motor through the appropriate aperture. Refitting V8 Petrol only 2. 7. Reverse procedures 6 to 1 ensuring the fan supply wiring is routed and securely clipped so that the f-y 23. Ensure all adjustment bolts associated with the compressor are slack. wiring does not foul the fan blades. 18
AIR CONDITIONING- L.H. & R.H. STEERING 1821 CONDENSER AND RECEIVER/DRIER Removal 1. Place the vehicle in a well ventilated arca. 2. Stop the engine, open and secure the bonnet. 3. Remove the caps from the compressor service valves. Connect the gauge set for evacuation, and evacuate as detailed earlier. 4. Having evacuated the air conditioning system, open fully (turn anti -clockwise) the compressor service valves and disconnect the gauge set. Replace all caps to valve connections. 5. Release the four top and two side fixings securing the grille and nose assembly and remove. 6. Disconnect the wires at the rear of the horn, the air conditioning fan leads located across the top of the fan cowling frame and the electrical connector to the receivddrier. 7. Release the four bolts and large packing washers ~ 8. Remove the four nuts securing the fan cowling to NOTE: L.H. steering vehicle illustrated on R.H. steering vehicles the high pressure hose is on the side of the evaporator unit facing the engine, securing the cowling to the wing sides. the bottom bracket and lift clear. 9. Remove the two bolts securing thc bonnet striker support plate. 13. Release the high pressure pipe from the receiver/ drier, cap the pipc end connections. Condenser removal only 10. Release the top air conditioning hose and cap the ends to prevent moisture and dirt entering the system. 7 610 9 6 7 7 S 14. Release both air conditioning pipes from the condenser extension plate. Lift the condenser clear. Receiveddrier removal 15. 11. Lift the condenser from the bottom mounting lugs and carefully ease the condenser forwards as far as possible. 16. 12. Release the high pressure air conditioning hose complete with the sight glass, at the evaporator 17. connection. Cap the ends to prevent dirt or moisture entering the system. .-‘.;t:, .I... -> : .p. Whilst supporting with suitable spanners, unscrew pipe ends to prevent dirt or moisture entering the system. Release the receiver/drier clamp bolts and allow the assembly to drop clear of the condenser. Lift the receiveddrier from the condenser and discard. 11 is NOT recommended to refit the old unit. 19 the b~tt~m tifii~fi to the ieceii;eii’diiei. “Lap the
1821 AIR CONDITIONING - L.H. & R.H. STEERING EVAPORATOR - LH steering models NOTE: It is only necessary to evacuate the air conditioning system when removing the evaporator matrix or to change the expansion valve. Removal 5 1. Place the vehicle in a ventilated area away from 2. Stop the engine and secure the bonnet in an open open flames and heat sources. position. Refitting 18. Reverse procedures 17 to 15 using a new receiver/ drier unit. 19. Connect the high prcssurc pipe to the received drier. Using two spanners on each union, tighten the union noting that the sight glass remains in the vertical position. 20. Carefully locate the condenser into position, refit the fixings securing the condenser to the extension plate. Connect and tighten the air conditioning hose to the top of the condenser. Use two spanners on each union. 21. Refit the condenser to the bottom bracket. 22. Place the bonnet striker support plate into position, do not secure at this stage. 23. Fit the fan cowling support brackets. It will be necessary to lift thc bonnet striker support plate to permit the positioning of the fan cowling assembly to the condenser mounting lugs. 24. Secure the steady rods and the lower condenser mounting bracket. Do not tighten the bolts at this stagc. Reconnect the top horn electrical leads. 25. Loosely fit the four bolts and distance washers which support the bonnet striker support plate and fan cowling to the wing sides. 26. Tighten the lower condenser bracket bolts. 27. Adjust the condenser position with the bonnet striker support bracket assembly to obtain an equal distance from the radiator. Tighten the four side mounting bolts. 28. Tighten the four nuis and washers which sccure the fan cowling mounting. 29. Reconnect the electrical wiring for the fan assemblies, horn and receiveddrier. 30. Recheck the security of all fixings. 31. Refit the front nose and grille assembly and secure. 32. Evacuate, sweep and charge the air conditioning 20 system as previously described. Heater matrix and blower motor only 3. Remove the caps from the compressor service 4. Disconnect the low pressure valve from thc compressor and cap both ends to prevent dirt or moisture entering the system. 5. Using two suitable spanners remove the high pressure pipe from the evaporator side. Cap both ends to prevent dirt or moisture entering the system. valves and close (turn clockwise) fully. /-% >--. Evaporator matrix and expansion valve only 6. Remove the caps from the Compressor service valves and connect the gauge set for evacuating. described. 8. Open the compressor service valves and disconnect the gauge set. Cap all pipes and gauge connections 9. Release the fixings and remove the expansion tank to provide access to the air conditioning high and low pressure pipes. 7 r- .^^..^ +... &L,. -:.. -,.-,4:+:--:-* r.,r+om op *v,=.,,;n,,ci,, /. CVdLU41G LIIG U11 LUllUlllul~1~l~ 3ya~c.111 LLJ yncvnvuo~~ d- :- to prevent dirt or moisture entering the system. f, -::: k;d
AIR CONDITIONING - L.H. STEERING :.- 10. Whilst supporting both unions with suitable spanners unscrew the high and low pressure air conditioning pipes to the evaporator. Cap the pipe ends and evaporator inlets to prevent dirt or moisture entering the system. 18. Remove the screw, releasing the relay connector block. 19. All wiring on the top of the evaporator is now disconnected with the exception of the earth lead, this is disconnected when the evaporator mounting block is removed. 20. Using suitable pipe clamps, clamp the inlet and outlet coolant pipes at the base of the evaporator and release the two jubilee clips and detach, or drain the radiator. .. , * Evaporator unit 11. Disconnect the electrical leads fcedine the h 82 21. From inside the vehiclc remove the front passenger carpet and self tapping screws which retain the toe-board. Remove the toe-board. compressor clutch cycling switch. switch. and withdraw it. 12. Detach the vacuum pipes from the water valve 13. Remove the fixings securing the water valve switch 22. Release two bolts, 14. Remove the clip and cable connection from the evaporator heater flap rod. Use a new clip on reassembly. 15. Release the nylon cable retainer. 16. Detach the heater electric supply lead at the 17. Remove the relay from its connecting block connecting block. revealing one self tapping screw. 23. From inside the engine compartment remove the two upper evaporator mounting block bolts fitted to the engine bulkhead. This also releases the earthing leads. 24. Remove the bolt securing the angled bracket at the front of the evaporator casing. 21
IF1 AIR CONDITIONING - L.H. STEERING ST1416M e42 45 22
.::.::!,,, .. 25. Lift the evaporator clear of the vehicle and place ,,).... ;.*. on a bench with a suitable support underneath the case to ensure the heater pipes are not damaged. 26. Release the nuts and remove the bracket from underneath the evaporator casing. 27. Remove the wire clip and detach the dump valve located underneath. 28. Release the seven self tapping screws securing the outlet duct and carefully break the sealing compound around the edge of the duct and pull ducting plate away from evaporator body. 29. Remove the fifteen screws located around the cover seam, Remove the old sealing compound from the body and top cover. 30. Remove the four screws and four nuts from the top of the cover. 31. From the front of the unit remove the two screws adjacent to the low pressure pipe moulding. 32. At the side of the unit remove the two screws . adjacent to the air intake aperture. 33. Lift the top cover off whilst feeding the blower motor wiring and air control flap rod through their respective apertures, thus exposing the blower motor, heater matrix and air conditioning evaporator matrix. .,I. . ..., . .. - ,. ... .. , .. .. Blower motor unit removal only Expansion valve removal 43. Support the suction pipe union with suitable spanners and release. 44. Remove the bleed pipe retaining nut from the suction pipe. 45. Remove the spring clip retaining the expansion valve sensor pipe to the main suction pipe which now rcleases the expansion valve and high pressure pipe. Place valve on bench and unscrew the high pressure pipe from the expansion valve. 46. Seal and cap all apertures; discard all ‘0’ rings which are renewed on assembly. Refitting 47. Reverse procedures 46 to 11 noting that all threads, unions, ‘0’ rings are coated with rcfrigerant oil prior to fitting. NOTE: Depending upon which unit has been refitted reverse the appropriate procedures: Heater Matrix or Blower Motor 5 to 3 Evaporator Matrix or Expansion Valve 10 to 6 and then charge the air conditioning system as previously described with Refrigerant 12. RESISTOR BLOCK Removal 34. Remove the screws rctaining the motor unit to thc casing. 35. Release the three bracket retaining screws and withdraw motor and impeller. 36. Detach the star washer, spring clip and impeller. 37. Remove the two nuts from the motor shroud and lift clear. 1. Stop the engine and secure the bonnet in an open 2. Detach the blower motor wiring connector. 3. Remove the self tapping screw and lift the resistor position. block out. . ,. HeatedEvaporator matrices removal only 38. Lift the support ptate and insulation pad from the matrix. 39. From the bottom of the casing, remove the three screws adjacent to the dump valve outlet, in addition to the screws next to the heater pipes. 40. Lift the evaporator and heater matrices together with the supporting frame containing the air direction flap clear of the casing. 41. Detach the evaporator matrix by releasing the four screws, two at both ends of the support bracket. 42. Detach the heater matrix by removing the self- tapping screw. Refitting 4. Reverse procedures 3 to 1. 23
I82 I AIR CONDITIONING - R.H. STEERING EVAPORATOR BLOWER MOTOR - RH Steering models Rem o v a 1 1. Open and secure the bonnet. 2. Release the plastic tie retaining the carburetter breather pipe to the right hand air intake elbow. 3. Remove the pulsair pipe connected to the air intake elbow. 4. Remove the right hand air intake elbow. 5. Disconnect the clip and blower motor wiring. 6. Release the blower motor cover fixings and separate the casing slightly to allow the earth and Lucar connectors to be released. 7. Remove the cover ensuring that a mark is made on the casing to indicate the correct positioning of the blower motor when refitting. 8. Release the five self-tapping screws and withdraw the blower motor and impeller. It may be necessary to move the low pressure air conditioning pipe aside to provide sufficient clearance. 9. Remove the centre nut on the impeller and carefully ease the impeller from the blower motor shaft. Refitting Evaporator remove and refit - R.H. steering models For removal of the blower motor only, see section “Evaporator Blower Motor”. NOTE: It is only required to evacuate the air conditioning system when removing the evaporator matrix or changing the expansion valve. Rem o v a I 1. Place the vehicle in a ventilated area away from 2. Stop the engine and secure the bonnet in an open 3. Disconnect the battery. 4. Unscrew the radiator drain-plug and partially drain 5. Remove the air-cleaner. 6. Remove the caps from the compressor service open flames and heat sources. position. the radiator. valves. Heater matrix only 7. Fully close (turn clockwise) the high pressure 8. Fully open (turn anti-clockwise) the lalw pressure 9. Slowly disconnect the low prcssurc pipe from the valve. valve. compressor rotor lock adaptor plate. 10. Remove the plastic ‘0’ ring from the rotor lock seal. Cap and seal both unions to prevent dirt or moisture entering the system. pipe to the upper engine bracket. 12. Remove the two plastic ties, securing the insulation cover on the high pressure pipe and remove the cover. 13. Whilst supporting both unions with suitable 6., .. 11 11. Release the p:zstic :is ~~~~ifig the !CW P~~SSE~P 10. Reverse procedures 9 to 1 ensuring that all seals spanners, unscrew the high pressure air 24 are replaced. conditioning pipe from the evaporator.
AIR CONDITIONING - R.H. STEERING r- L%+ Evaporator matrix and expansion valve only 14. Evacuate the air conditioning system as previously described. 15. Open (turn anti-clockwise) the compressor service valves and disconnect the gauge set. Cap all pipes and gauge connections to prevent dirt or moisture entering the system. 16. Remove the insulating cover on the low pressure pipe. 17. Whilst supporting both unions with suitable spanners, unscrew the low pressure air conditioning pipe from the evaporator. 18. Cap both ends to prevent dirt or moisture entering the system. 19. Remove the two plastic ties, securing the insulation cover on the high pressure pipe and remove the cover. 20. Whilst supporting both unions with suitable ~ spanners, unscrew the high pressure air :.,c*-..:‘ 0 *It ,A.. 1 It I‘ conditioning pipe from the evaporator. 82 Evaporator unit 21. Remove the self tapping screw securing the air 22. Disconnect the two ‘Ronco’ thermostat wires. 23. Disconnect the two heater hoses from the side of the evaporator unit. 24. Remove the vacuum pipe from the water valve switch. 25. Remove the clip and cable connection from the evaporator air flap rod. Use a new clip on reassem bly. control flap solenoid. 26. Disconnect the blower motor wiring connections. 27. Remove the screw retaining the blower motor wiring tot he blower motor housing. 28. Remove the two bolts securing the blower motor resistor block to the engine compartment. 29. Remove the bolt securing the front support brackct to the blower motor housing. 30. From inside the vehicle rcmove the front passenger carpet and five self tapping screws which retain the toe -box cover. 31. Release the four bottom mounting bracket bolts, ensuring that the spacing washers from the two innermost bolts are retrieved from the engine bulkhead side. 32. From inside the engine compartment remove the two 13 mm upper evaporator mounting bracket bolts fitted to the engine bulkhead. 33. Lift the evaporator clear of the vehicle and place on a bench with the blower motor cover facing up. 34. Turn the evaporator unit around and remove thc fixings retaining the blower motor housing duct. 35. Remove the “Ranco” thermostat from the top of the unit. 36. Remove the seven self -tapping screws securing thc top and bottom halvcs of the unit togethcr. 37. Remove the eight screws from the right hand side of the unit. 38. Peel back the sponge pad on the outlet duct to expose the last retaining screw. Remove the screw. 39. Remove the two screws on the top of the unit. 40. Remove the joint sealant around the seam and separate the two halves of the evaporator cover assembly . 41. Remove the heater matrix from thc evaporator casing. 25
I82 I AIR CONDITIONING - R.H. STEERING Evaporator matrix and Expansion valve only 42. Release the screws attached to the blower motor retaining plate and remove the plate. 43. Remove the blower motor inner housing. 44. Remove the bleed -pipe retaining nut from the low pressure pipe. 45. Remove the spring clip retaining the expansion valve sensor pipe to the low pressure pipe and remove the expansion valve and high pressure pipe. 46. Unscrew the high pressure pipe from the expansion valve. 47. Seal and cap all pipes and connections to prevent dirt or moisture entering the system. Discard all ‘0’ rings, which are renewed on refitting. 48. Release the two nuts adjacent to the dump valve. 49. Remove the two evaporator mounting screws from each side of the casing. 50. Release the two uppcr evaporator mounting bracket screws and pull the bracket away from the evaporator. 51. Lift the evaporator matrix from the casing with thc two side plates and place on a bench. + Refitting 52. Reverse procedures 51 to 21, ensuring that all threads, unions and ‘0’ rings are coated with refrigerant oil prior to fitting. Discard all old ‘0’ rings and renew on refitting. When reversing procedure 31, ensurc that the spacing washers are fitted to the two innermost bolts. NOTE: Depending upon which component has been removed, reverse the appropriate procedure as follows: Evaporator matrix and expansion valve 20 to 2 Heater matrix 13 to 2. 26