Defender (1993+). Manual — part 96

AIR CONDITIONING

CONDENSER

AND

RECEIVER/DRIER

Removal

1.

Place the vehicle in a well ventilated area.

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 receiver/drier.

7. Release the four bolts and large packing

washers securing the cowling

to

the wing

sides.

8.

Remove the four nuts securing the fan

cowling to the bottom bracket and lift clear.

9.

Remove the two bolts securing the bonnet
striker support plate.

13.

Release the high pressure pipe from the

receiver/drier, cap the pipe end connections.

Condenser removal

only

10. Release the top air conditioning hose and cap

the ends to prevent moisture and dirt entering
the system.

14.

Release both air conditioning pipes from the

condenser extension plate. Lift the condenser
clear.

Receiver/drier removal

15.

Whilst supporting with suitable spanners,
unscrew the bottom union to the receiver/drier.
Cap the pipe ends

to

prevent dirt or moisture

entering the system.

16.

Release the receiver/drier clamp bolts and

allow me assembly

to

drop clear of the

lugs and carefully ease the condenser

17. Lift the receiver/drier from the condenser and

forwards as far as possible.

discard. It is

NOT

recommended to refit the

old unit.

11. Lift the condenser from the bottom mounting

condenser.

12.

Release the high pressure air conditioning
hose complete with the sight glass, at the
evaporator connection. Cap the ends to
prevent dirt or moisture entering the system.

18

REISSUED:

FEB

1993

AIR CONDITIONING

EVAPORATOR

NOTE: It

is

only necessary to evacuate the air

conditioning

system

when

removing

the

evaporator matrix or to change the expansion
valve.

Removal

1.

Place the vehicle in a ventilated area away

from open flames and heat sources.

2. Stop the engine and secure the bonnet in an

open position.

Heater matrix and blower motor only

Refitting

3. Remove the caps from the compressor

service valves and close (turn clockwise) fully.

4.

Disconnect the low pressure valve from the

receiver/drier unit.

compressor and cap both ends to prevent dirt

receiver/drier. Using two spanners on each

5.

Using

two

suitable spanners remove the high

union, tighten the union noting that the sight

pressure pipe from the evaporator side. Cap

glass remains in the vertical position.

both ends to prevent dirt or moisture entering

refit the fixings securing the condenser to the
extension plate.

21. Connect and tighten the air conditioning hose

to

the top of the condenser. Use two spanners

on each union.

22. Refit the condenser to the bottom bracket.
23. Place the bonnet striker support plate into

position, do not secure at this stage.

24. Fit the fan cowling support brackets. It will be

necessary to lift the bonnet ‘striker support
plate to permit the positioning of the fan
cowling assembly to the condenser mounting
lugs.

25.

Secure the steady rods and the lower
condenser mounting bracket. Do not tighten
the bolts at this stage. Reconnect the top horn
electrical leads.

26. Loosely fit the four bolts and distance washers

which support the bonnet striker support plate
and fan cowling to the wing sides.

27. Tighten the lower condenser bracket bolts.
28.

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.

29. Tighten the four nuts and washers which

secure the fan cowling mounting.

30.

Reconnect the electrical wiring for the fan
assemblies, horn and receiver/drier.

31. Recheck the security of all fixings.

entering the system.

32. Refit the front nose and grille assembly and

secure.

33. Evacuate,

sweep

and

charge the

air

conditioning system as previously described.

18. Reverse procedures 15 to 17 using a new

19. Connect the high pressure pipe to the

or moisture entering the system.

20. Carefully locate the condenser into position,

the system.

Evaporator matrix and expansion valve only

6.

Remove the caps from the compressor
service valves and connect the gauge set for
evacuating.

7. Evacuate the air conditioning system as

previously described.

8. Open the compressor service valves and

disconnect the gauge set. Cap all pipes and
gauge connections to prevent dirt or moisture

9. Release the fixings and remove the expansion

tank to provide access to the air conditioning
high and low pressure pipes.

REISSUED:

FEB

1993

19

AIR

CONDITIONING

10,

Whilst supporting both unions with suitable

18.

Remove the screw securing the fuse holder,

then refit both screws to retain

the

resistor

block in the evaporator case.

19. All wiring on the top of the evaporator is now'

disconnected with the exception of the ground
lead, this is disconnected when the evaporator

top fixings are 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.

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.

Evaporator unit

11.

Disconnect the electrical leads feeding the

compressor clutch cycling switch.

12.

Detach the vacuum pipes from the water

valve switch.

13.

Remove the fixings securing the water valve

switch and withdraw it.

14. Remove the clip and cable connection from

the evaporator heater Rap rod. Use a new clip
on reassembly.

15.

Release the nylon cable retainer.

16.

Detach the resistor block electrical connector.

17.

Remove the relay module from its socket and
remove the self tapping screw to release the

socket.

21. From inside the vehicle remove the front

passenger carpet and self tapping screws
which retain the toe-board. Remove the

toe-board.

22. Release the

two

bolts.

23.

From inside the engine compartment remove

the two bolts from behind the relay module

securing the evaporator to the bulkhead. This
also releases the ground leads.

24. Remove the bolt securing the front of the

evaporator casing.

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.

20

REISSUED:

FEB

1993

REISSUED: FEB

1993

21