Discovery 2. Manual — part 717

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

82-32

REPAIRS

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

82-34

REPAIRS

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.