Automatic A/c-Heater System: Removal & Installation Land Rover Discovery II

REMOVAL & INSTALLATION

Removal & Installation (Front)

Obtain radio security code. Disconnect negative battery cable. Remove radio. Release radio bracket clips. Remove radio bracket. Working through radio opening, release control unit from instrument panel. Disconnect 3 connectors and remove control unit. To install, reverse removal procedure. Enter security code and check radio for correct operation. see scheme 1

Removal & Installation (Rear)

Disconnect negative battery cable. Open rear door. Unclip rear A/C switch from headliner panel. Disconnect electrical connectors. Remove rear A/C control panel. (Scheme 7) To install, reverse removal procedure.

Scheme 7

1. Disconnect negative battery cable. Drain engine cooling system. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect heater hoses in engine compartment. Disconnect A/C pipes to evaporator and discard "O" rings. Install plugs to open A/C connections to prevent contamination. Remove instrument panel. See «INSTRUMENT PANEL»(ref-11574-S19440814622000112900000) .
2. Remove screws securing rear heater ducting and remove ducting. Remove high and low pressure pipe clip. Disconnect blower motor electrical connector. Remove blower motor. Remove center console support bracket. Remove right side instrument panel support bracket. Disconnect both evaporator drain hoses. Remove front heater ducting. Remove 4 nuts and bolt securing heater assembly. Release heater assembly from firewall grommet and remove from vehicle.
3. To install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000) . Evacuate and charge A/C system. Refill cooling system.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove rear exhaust heat shield. Remove 2 bolts securing A/C pressure pipes, release pipes and discard "O" rings. see scheme 4 Install plugs to open A/C connections to prevent contamination.
2. Remove 2 bolts securing grommet flange to body and remove flange. Remove left rear lower trim casing. Remove 5 bolts securing seat support bracket and remove bracket. Disconnect A/C harness connectors from body harness. Remove 2 clips securing ducting to A/C assembly and release ducting.
3. Remove 4 bolts securing evaporator assembly and remove assembly. To install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000). Evacuate and charge A/C system.

Removal & Installation (Air Distribution Control)

Disconnect negative battery cable. Remove blower motor assembly. See BLOWER MOTOR . Release clip securing operating lever and remove lever from linkage. Remove 3 actuator screws. Disconnect actuator electrical connector and remove actuator. Release clip securing operating lever to actuator and remove lever. Remove support bracket. To install, reverse removal procedure.

Removal & Installation (Blend Air Temperature Control)

1. Disconnect negative battery cable. If removing driver's side blend air temperature control flap actuator motor, remove A/C-heater unit. See «A/C-HEATER UNIT»(ref-11574-S27026732232000113000000) . If removing passenger's side blend air temperature control flap actuator motor, remove front blower motor. See «BLOWER MOTOR»(ref-11574-S21974532862000112900000) .
2. On either actuator, remove actuator electrical connector. Release clip securing operating lever, release lever and remove actuator. To install, reverse removal procedure.

Removal & Installation (Recirculation Flap)

Remove passenger side knee bolster. Remove glove box. Remove Body Control Module (BCM) bolt, release BCM from retaining peg and remove BCM. Remove 2 nuts securing Automatic Temperature Control Electronic Control Unit (ATC ECU) and lower ATC ECU to gain access to actuator screws. Disconnect actuator connector. Remove 2 actuator screws, disconnect operating lever and remove actuator. To install, reverse removal procedure.

1. Remove 4 instrument under panel studs and remove under panel. Remove glove box. Disconnect negative battery cable. Disconnect blower motor electrical connectors. (Scheme 8) Remove 8 passenger's side instrument panel mounting bolts.
2. Carefully ease instrument panel away from firewall. Remove 3 blower motor support bracket bolts and remove bracket. Remove 2 blower motor assembly nuts and remove blower motor assembly.
3. To install, reverse removal procedure. Tighten instrument panel mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000).

Scheme 8

Remove third-row seat (if equipped). Remove rear lower trim casing. Remove 5 bolts securing third-row seat support bracket and remove bracket. Disconnect blower motor connector and release hose from casing. Remove screws securing blower motor and remove motor from casing. To install, reverse removal procedure. Tighten rear seat support bracket bolts to specific. See TORQUE SPECIFICATIONS .

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove battery cover and disconnect negative battery cable. Remove upper fan cowl. Remove viscous fan. Turn drive belt tensioner and release drive belt.
2. Disconnect compressor clutch connector. (Scheme 9) Remove 2 A/C pipes-to-compressor bolts and discard "O" rings. Install plugs to open A/C connections to prevent contamination. Remove 4 compressor-to-mounting bracket bolts. Remove compressor.
3. To install, ensure correct amount of refrigerant oil is installed. See «COMPRESSOR OIL LEVEL»(ref-11574-S42602474862000112900000) under ADJUSTMENTS. Clean compressor dowels and dowel holes. Position compressor to mounting bracket and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000).
4. Remove caps from compressor and pipe connections. Clean compressor and pipe connections. Lubricate NEW "O" rings with refrigerant oil and install to compressor. Position A/C pipes-to-compressor and tighten bolts to specification. Reconnect compressor clutch connector. Install drive belt. Evacuate and charge A/C system.

Scheme 9

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove front grille. Remove radiator. Disconnect dual-pressure switch connector. Remove bolt securing evaporator pipe to condenser. Disconnect evaporator pipe from condenser and discard "O" ring.
2. Remove bolt securing evaporator pipe to receiver-drier. Disconnect evaporator pipe from receiver-drier and discard "O" ring. Install plugs to open A/C connections to prevent contamination. Remove 3 remaining bolts securing cooling fan support rails to condenser. Remove condenser with receiver-drier attached.
3. Remove bolt securing adapter block to receiver-drier. Remove adapter block from receiver-drier and discard "O" ring. Remove bolt securing condenser pipe to receiver-drier. Remove receiver-drier clamp bolt and remove receiver-drier from bracket. Remove and discard "O" ring from condenser pipe.
4. Remove 2 remaining bolts securing receiver-drier brackets and condenser left mounting bracket to condenser. Remove mounting bracket assembly. Remove remaining bolt securing condenser right mounting and remove mounting. Remove sealing strip from outer upper seam of condenser. Remove captive nut plates from condenser.
5. To install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten mounting nuts and bolts and A/C line connections to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000) . Evacuate and charge A/C system. Refill engine cooling system.

1. Remove A/C-heater unit. See «A/C-HEATER UNIT»(ref-11574-S27026732232000113000000). Remove firewall and evaporator pipe seals. Disconnect evaporator thermistor connector.
2. Remove 2 temperature control actuator-to-evaporator casing screws. Remove 2 coolant pipe support bracket-to-casing screws. Remove coolant pipe saddle clamp-to-casing screws and remove saddle. Remove heater core. Remove 5 casing screws. (Scheme 10)
3. Remove evaporator casing and insulation. Remove evaporator assembly. Remove evaporator thermistor. Remove covering from thermostatic expansion valve and release 2 clips securing valve to pipe. Release 2 unions securing thermostatic expansion valve and remove valve. Remove and discard "O" rings. Release pipe union, remove pipe and discard "O" ring.
4. To install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Connect pipe unions and mounting bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000). Evacuate and charge A/C system. Refill engine cooling system.

Scheme 10

1. Remove rear A/C unit. See «A/C-HEATER UNIT»(ref-11574-S27026732232000113000000) . Remove rear A/C unit wiring harness. Remove thermostatic expansion valve insulation. Release rear blower relay from support bracket. Remove ducting seal. Remove 4 lower casing screws and remove lower casing. Remove and discard "O" rings from evaporator lines. Plug thermostatic expansion valve-to-evaporator connections.
2. Remove 6 A/C unit case half screws. Remove 4 A/C unit case half clips. Separate A/C unit case while removing thermostat probe from evaporator core. Remove evaporator. To install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil.

Remove A/C-heater unit. See A/C-HEATER UNIT. Remove 2 right side footwell outlet screws. Remove heater pipe clamps. Slide heater core out of heater case. (Scheme 11) Disconnect 2 heater pipe clips. To install, reverse removal procedure.

Scheme 11

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove key from ignition switch. Disconnect both battery cables, negative cable first. Wait at least 10 minutes before starting work. Remove radio. Remove steering wheel. Remove steering column nacelle. Remove center console.
2. Remove "A" post trim panels. Remove 6 clips securing both lower closing panels to instrument panel and remove closing panels. Remove mats from instrument panel. Remove 2 screws and release instrument cowl from 2 clips on instrument panel. Disconnect switch connectors in instrument cowl and remove cowl. Remove 4 screws securing instrument pack to instrument panel. Disconnect 2 instrument pack connectors and remove pack.
3. Remove instrument panel access panel. Remove 4 nuts securing instrument panel to steering column bracket. Disconnect 3 connectors connecting main body harness to instrument panel harness. Disconnect instrument panel harness connector from fuse box. Remove glove box.
4. Disconnect heater control connectors. Separate Blue section from In-Car Entertainment (ICE) connector. Release coaxial cables from instrument panel. Disconnect passenger's side air bag connector. Disconnect blower motor connector. Working through glove box opening, remove 4 bolts securing instrument panel to body.
5. Remove 4 bolts securing lower edge of instrument panel to mounting brackets on transmission tunnel. Remove 4 bolts securing lower edge of instrument panel to brackets on "A" post. With assistance carefully remove instrument panel from vehicle. To install, reverse removal procedure. Tighten mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000) .

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove 3 scrivets securing top of grille to hood locking support. Release lower corners of grille from body and remove grille. Disconnect dual-pressure switch connector.
2. Remove condenser pipe-to-receiver-drier bolt and disconnect condenser pipe from receiver-drier. Install plugs to open A/C connections to prevent contamination. Remove bolt securing evaporator pipe to receiver-drier and disconnect evaporator pipe from receiver-drier.
3. Remove receiver-drier mounting bracket bolts and remove receiver-drier assembly. Remove receiver-drier from mounting bracket. Remove dual-pressure switch. Remove "O" ring from switch and discard.
4. To install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11574-S00862203142000112700000) . Evacuate and charge A/C system.