Defender (1999-2002). Manual - part 120

AIR CONDITIONING

ADJUSTMENT

REFRIGERANT RECOVERY, RECYCLING,
RECHARGING

Service repair no - 82.30.02

WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must

only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.

WARNING: All operations must be carried
out in a well ventillated area away from
open flame and heat sources.

WARNING: Wear eye and hand safety
protection.

CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.

An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover R134a refrigerant from the air conditioning
system; to filter and remove moisture; to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.

The operator must adhere to the equipment
manufacturer’s instructions.

Refrigerant 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.

NOTE: 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.

8. Close valves on refrigerant station.
9. Turn Main switch to ’OFF’.

10. Close valves on connectors.
11. Disconnect high and low pressure hoses from

connectors.

12. Fit dust caps to connectors.
13. Open tap at rear of station to drain refrigerant oil

recovered from system.

14. Measure and record quantity of refrigerant oil

recovered from system.

15. Close tap at rear of station.

Evacuation

CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating

and recharging the system.

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.

NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the

system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes. Next check the high
pressure lines.

NOTE: The system must be evacuated
immediately before recharging
commences. Delay between evacuation

and recharging is not permitted.

AIR CONDITIONING

ADJUSTMENT

Recharging

WARNING: Refrigerant must always be
recycled before re-use, to ensure that the
purity of the refrigerant is high enough for

safe use within 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 re-cycle the
refrigerant to the required level of purity.

WARNING: A R134a Refrigerant Recovery
Recycling Recharging station must not be
used with any other type of refrigerant.

WARNING: R134a refrigerant from
domestic and commercial sources must
not be used in motor vehicle air

conditioning systems.

CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.

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 correct quantity of refrigerant oil into oil

charger.

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 drop.

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. If the full charge is not accepted by the system,

start the engine and run it at 1,500 rev/min for a
minimum of 2 minutes. Switch on the air
conditioning system, open the vehicle windows,
set the temperature control to cold and the
blower switch to maximum.

13. Consult Refrigerant station instruction manual for

correct procedure to complete the charge.

14. Turn Main switch to ’OFF’.
15. Close valves on connectors.
16. Disconnect high and low pressure hoses from

connectors.

17. Fit dust caps to connectors.
18. Carry out performance test on air conditioning

system.

AIR CONDITIONING

REPAIR

COMPRESSOR

Service repair no - 82.10.20

Remove

1. Remove engine acoustic cover. See ENGINE ,

Repair.

2. Depressurise A/C system. See Adjustment.
3. Remove auxiliary drive belt. See

ELECTRICAL, Repair.

4. Drain cooling system. See COOLING

SYSTEM, Adjustment.

5. Disconnect multiplug from compressor.
6. Remove 2 bolts securing air conditioning pipes

to compressor and discard ’O’ rings.

CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.

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

10. Position compressor to mounting bracket and

tighten bolts to 25 Nm (18 lbf.ft) .

11. Remove caps from compressor and pipe

connections.

12. Clean compressor and pipe connections.
13. Lubricate new ’O’rings with refrigerant oil and fit

to compressor.

14. Position A/C pipes to compressor and tighten

bolts to 9 Nm (7 lbf.ft) .

15. Connect multiplug to compressor.
16. Position top hose and secure with clips.
17. Refill cooling system. See COOLING SYSTEM,

Adjustment.

18. Fit auxiliary drive belt. See ELECTRICAL,

Repair.

19. Recharge A/C system. See Adjustment.
20. Fit engine acoustic cover. See ENGINE ,

Repair.

AIR CONDITIONING

REPAIR

MOTOR - CONDENSER FAN

Service repair no - 82.15.01

Remove

1. Remove 6 screws and remove radiator grille.

2. Disconnect fan multiplug and release multiplug

holder from retaining clip.

3. With assistance remove 4 nuts and bolts

securing motor to condenser.

4. Remove motor.

Refit

5. Position motor to condenser and with assistance

tighten nuts and bolts to 8 Nm (6 lbf.ft) .

6. Connect motor multiplug.
7. Position radiator grille and secure with screws.

RECEIVER DRIER

Service repair no - 82.17.03

Remove

1. Recover refrigerant from A/C system. See

Adjustment.

2. Remove 2 bolts securing pipe unions to receiver

drier.

3. Release pipes and discard ’O’ rings.

CAUTION: Immediately cap all air
conditioning pipes to prevent ingress of
dirt and moisture into the system.

4. Remove 2 bolts securing receiver drier mounting

bracket to chassis.

5. Remove receiver drier, slacken clamp bolt and

remove bracket.

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