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Contents Wiring diagrams Section: Heating and Ventilation All sections

Refit Land Rover Discovery III

Heating and Ventilation 42 illustrations ~2181 words

Refit

  1. Fit switches to heater control housing.
  2. Position heater control assembly and connect multiplugs to switches and illumination.
  3. Connect heater control cables and secure outer cable abutments to casing.
  4. Fit louvre panel assembly. Refer to «REFIT»(ref-207935-S16445055152005120400000) .

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Scheme 12: Remove
Scheme 12: Remove

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Scheme 15
  1. Driver temperature control and air flow control cables: Release fixings and lower fascia fuse box access cover.
  2. Passenger temperature control cable: Remove 4 screws securing glove box, release catch and remove glove box.
  3. Remove louvre panel assembly. Refer to «REMOVE»(ref-207935-S18045650422005120400000) .
  4. Release control cable abutment from control housing and disconnect inner cable from control.
  5. Release clip securing control outer cable to heater case and disconnect inner cable from flap lever.
  6. Remove control cable.
  1. Fit new control cable, connect inner cable to control and secure abutment to control housing.
  2. Fit other end of inner cable to flap lever.
  3. Position control to maximum heat for temperature control cables or de-mist for air flow control cable, hold flap lever in fully closed position and secure outer cable in clip on heater casing.
  4. Refit louvre panel assembly. Refer to «REFIT»(ref-207935-S16445055152005120400000) .
  5. Driver temperature and air flow control cables: Close fuse access cover and secure fixings.
  6. Passenger temperature control cable: Refit glove box and secure with bolts.

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Scheme 16: Remove
Scheme 16: Remove

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Scheme 20
  1. Remove 4 studs securing passenger toe board and remove toe board.
  2. Remove 4 screws securing glove box, release catch and remove glove box.
  3. Remove bolt securing BCM, release BCM from retaining peg and lower BCM.
  4. Remove 2 nuts securing ECU assembly and lower ECU assembly to gain access to servo screws.
  5. Disconnect multiplug from servo.
  6. Remove 2 screws securing servo.
  7. Release servo, disconnect operating lever and remove servo.
  1. Position servo and connect operating lever.
  2. Fit and tighten screws securing servo.
  3. Connect multiplug to servo.
  4. Position ECU assembly, fit and tighten nuts.
  5. Position BCM, fit and tighten bolt.
  6. Position toe board and secure with studs.
  7. Position glove box, fit and tighten screws.

Scheme 21

Scheme 21: Remove
Scheme 21: Remove
  1. Remove louvre panel assembly. Refer to «REMOVE»(ref-207935-S18045650422005120400000) .
  2. Disconnect multiplug from recirculation switch.
  3. Remove recirculation switch from heater control panel.
  1. Fit recirculation switch to heater control panel and connect multiplug.
  2. Fit louvre panel assembly. Refer to «REFIT»(ref-207935-S16445055152005120400000) .

Scheme 22

Scheme 22: Remove
Scheme 22: Remove
  1. Disconnect battery earth lead.
  2. Remove heater assembly. Refer to «HEATER ASSEMBLY - MODELS WITHOUT AIR CONDITIONING»(ref-207938-S28805529652005120400000) or «HEATER ASSEMBLY - MODELS WITH AIR CONDITIONING»(ref-207938-S08939157412005120400000) .
  3. Release clip securing operating lever and release the lever from linkage.
  4. Remove 3 screws securing servo support bracket to casing and release servo.
  5. Disconnect multiplug from servo and remove servo.
  6. Release clip securing operating lever to servo and remove lever.
  7. Remove 2 screws securing support bracket and remove support bracket.
  1. Position support bracket to servo and secure with screws.
  2. Position servo lever to servo and secure clip.
  3. Connect multiplug to servo.
  4. Position servo to casing and secure with screws.
  5. Connect operating lever to servo and secure with clip.
  6. Fit heater assembly. Refer to «HEATER ASSEMBLY - MODELS WITHOUT AIR CONDITIONING»(ref-207938-S28805529652005120400000) or «HEATER ASSEMBLY - MODELS WITH AIR CONDITIONING»(ref-207938-S08939157412005120400000) .
  7. Connect battery earth lead.

Scheme 23

Scheme 23: Remove
Scheme 23: Remove
  1. Disconnect battery earth lead.
  2. Driver side: Remove heater assembly. Refer to «HEATER ASSEMBLY - MODELS WITHOUT AIR CONDITIONING»(ref-207938-S28805529652005120400000) or «HEATER ASSEMBLY - MODELS WITH AIR CONDITIONING»(ref-207938-S08939157412005120400000) .
  3. Passenger side: Remove blower assembly. Refer to «BLOWER ASSEMBLY»(ref-207938-S12491082552005120400000) .
  4. Disconnect multiplug from servo.
  5. Remove 3 screws securing servo to casing and release servo.
  6. Release clip securing operating lever, release the lever and remove servo. lever.
  1. Connect operating lever to servo and secure with clip.
  2. Position servo to casing, engage locating pegs and secure with screws.
  3. Connect multiplug to servo.
  4. Driver side: Fit heater assembly. Refer to «HEATER ASSEMBLY - MODELS WITHOUT AIR CONDITIONING»(ref-207938-S28805529652005120400000) or «HEATER ASSEMBLY - MODELS WITH AIR CONDITIONING»(ref-207938-S08939157412005120400000) .
  5. Passenger side: Fit blower assembly. Refer to «BLOWER ASSEMBLY»(ref-207938-S12491082552005120400000) .
  6. Connect battery earth lead.

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Scheme 24: Remove
Scheme 24: Remove

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Scheme 25
  1. Remove both windscreen side finishers.
  2. Remove caps from windscreen wiper arms.
  3. Remove nuts securing wiper arms to wiper linkage.
  4. Remove both wiper arms.
  5. Remove lock nuts from wiper linkage and collect washer and rubber spacers.
  6. Remove 2 trim clips and center bolt securing plenum air intake to body.
  7. Remove plenum air intake.
  1. Fit plenum air intake.
  2. Fit trim clips and center bolt securing plenum air intake to body.
  3. Fit rubber spacers and washers to wiper linkage.
  4. Fit locknuts to wiper linkage and tighten to 7 Nm (5.2 lbf.ft).
  5. Fit wiper arms to wiper linkage.
  6. Fit nuts securing wiper arms to wiper linkage and tighten to 17 Nm (13 lbf.ft).
  7. Fit caps to wiper arms.
  8. Fit both windscreen side finishers.

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Scheme 26: Remove
Scheme 26: Remove

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Scheme 31
  1. Drain cooling system. Refer to «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .
  2. Diesel models: Remove 3 bolts and remove engine cover.
  3. Release clips and disconnect coolant hoses from heater pipes. CAUTION: Always fit plugs to open connections to prevent contamination.
  4. Remove fascia assembly. Refer to «REMOVE»(ref-207935-S27829667182005120400000) .
  5. Disconnect harness multiplug from heater blower motor.
  6. Remove bolt and 2 nuts securing heater blower housing assembly to body and remove blower.
  7. Disconnect 2 drain tubes from base of heater.
  8. Remove 2 screws securing console bracket to tunnel and remove bracket.
  9. Release radio coaxial cable from behind heater pipes.
  10. Protect the carpet from coolant spillage.
  11. Remove 4 nuts and 1 bolt securing heater to body.
  12. Remove heater from vehicle.
  13. Remove 2 screws securing heater RH and LH footwell outlet duct to heater casing and remove ducts.
  14. Remove 2 screws securing matrix pipe bracket to heater casing.
  15. Remove screw securing pipe clamp to heater casing and remove clamp.
  16. Carefully remove matrix from heater.
  1. Fit matrix into heater casing.
  2. Fit screws securing pipe bracket to heater casing.
  3. Fit pipe clamp and secure with screw.
  4. Fit heater ducts and secure with screws.
  5. Position heater assembly to vehicle, ensure heater coolant pipe grommet is correctly located in bulkhead and secure with nuts and bolt.
  6. Fit radio coaxial cable behind heater pipes.
  7. Fit console bracket and secure with screws.
  8. Connect drain tubes to base of heater.
  9. Fit blower unit to heater and secure to body with nuts and bolt.
  10. Connect harness multiplug to blower motor.
  11. Fit fascia assembly Refer to «REFIT»(ref-207935-S10624864452005120400000) .
  12. Connect heater hoses and secure with clips.
  13. Diesel models: Fit engine cover and secure with bolts.
  14. Refill cooling system Refer to «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .

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Scheme 32: Remove
Scheme 32: Remove

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Scheme 37
  1. Drain cooling system. Refer to «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .
  2. Evacuate air conditioning system. Refer to «EVACUATION»(ref-207939-S00025840442005120400000) .
  3. Release 2 clips securing heater hoses to heater and release hoses.
  4. Remove 2 bolts securing air conditioning pipes to evaporator, release pipes and discard 'O' rings. CAUTION: Always fit plugs to open connections to prevent contamination.
  5. Remove fascia. Refer to «REMOVE»(ref-207935-S27829667182005120400000) .
  6. Remove screws securing rear heater ducting and remove ducting.
  7. Disconnect multiplug from heater motor.
  8. Remove 2 nuts and bolt securing heater motor assembly and remove motor assembly from heater casing.
  9. Remove 2 screws securing center console support bracket and remove bracket.
  10. Remove 2 nuts securing RH fascia support bracket and remove bracket.
  11. Disconnect both evaporator drain hoses.
  12. Remove front heater ducting.
  13. Remove 4 nuts and bolt securing heater assembly, release heater assembly from bulkhead grommet and remove from vehicle.
  1. Position heater assembly to bulkhead, locate heater in bulkhead grommet.
  2. Fit nuts and bolt securing heater and tighten to 16 Nm (12 lbf.ft).
  3. Position RH fascia support bracket, fit and tighten nuts.
  4. Fit front heater ducting.
  5. Position center console support bracket, fit and tighten screws.
  6. Connect evaporator drain hoses.
  7. Position heater motor to heater casing, fit nuts and bolt and tighten to 19 Nm (14 lbf.ft).
  8. Connect multiplug heater motor.
  9. Position rear heater ducting and secure with screws.
  10. Fit fascia. Refer to «REFIT»(ref-207935-S10624864452005120400000) .
  11. Using new 'O' rings, position air conditioning pipes to evaporator fit bolts and tighten to 5 Nm (3.7 lbf.ft).
  12. Position heater hoses and secure hose clips.
  13. Recharge air conditioning system. Refer to «RECHARGING»(ref-207939-S08511998252005120400000) .
  14. Refill cooling system. Refer to «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .

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Scheme 38: Remove
Scheme 38: Remove

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Scheme 40
  1. Remove 4 studs securing toe board and remove toe board.
  2. Remove 4 screws securing glove box, release catch and remove glove box.
  3. Disconnect battery earth lead.
  4. Disconnect multiplugs from blower motor.
  5. Remove 8 bolts securing passenger side of fascia panel.
  6. Carefully ease fascia away from bulkhead
  7. Remove 3 bolts securing blower motor support bracket and remove bracket.
  8. Remove 2 nuts securing motor assembly.
  9. Release blower motor assembly from heater and maneuver from under fascia.
  1. Position blower motor assembly under fascia and locate to heater casing.
  2. Position support bracket, fit and tighten nuts and bolts.
  3. Align fascia, fit bolt to support bracket and tighten to 26 Nm (19 lbf.ft).
  4. Connect multiplugs to blower motor.
  5. Connect battery earth lead.
  6. Fit glove box, align hinges and tighten screws.
  7. Position toe board and secure with studs.

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Scheme 41: Remove
Scheme 41: Remove

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Scheme 43
  1. Remove 4 studs securing toe board and remove toe board.
  2. Remove 4 screws securing glove box, release catch and remove glove box.
  3. Remove screw securing harness to blower motor and release harness.
  4. Disconnect multiplug from blower motor.
  5. Remove 3 screws securing blower motor to casing and remove blower motor.
  1. Position blower motor to casing and secure with screws.
  2. Connect multiplug to blower motor.
  3. Position harness and secure clip with screw.
  4. Fit glove box, align hinges and tighten screws.
  5. Position toe board and secure with studs.

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Scheme 44: Remove
Scheme 44: Remove

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Scheme 46
  1. Remove 4 studs securing toe board and remove toe board.
  2. Remove 4 screws securing glove box, release catch and remove glove box.
  3. Disconnect multiplug from resistor.
  4. Remove screws securing resistor, release and remove resistor.
  1. Position resistor and secure with screw.
  2. Connect multiplug to resistor.
  3. Position glove box, fit and tighten screws.
  4. Position toe board and secure with studs.

Scheme 47

Scheme 47: Remove
Scheme 47: Remove
  1. Remove heater assembly. Refer to «HEATER ASSEMBLY - MODELS WITHOUT AIR CONDITIONING»(ref-207938-S28805529652005120400000) or «HEATER ASSEMBLY - MODELS WITH AIR CONDITIONING»(ref-207938-S08939157412005120400000) .
  2. Remove 2 screws securing coolant pipe saddles and remove saddles.
  3. Loosen screws securing coolant pipes to matrix, release clamps and remove coolant pipes.
  4. Remove and discard 'O' rings.
  5. Remove heater matrix.
  1. Position heater matrix, using new 'O' rings fit coolant pipes and align clamps.
  2. Fit saddle clamps and secure with screws
  3. Tighten coolant pipe clamp screws.
  4. Fit heater assembly. Refer to «HEATER ASSEMBLY - MODELS WITHOUT AIR CONDITIONING»(ref-207938-S28805529652005120400000) or «HEATER ASSEMBLY - MODELS WITH AIR CONDITIONING»(ref-207938-S08939157412005120400000) .

Scheme 48

Scheme 48: Remove
Scheme 48: Remove
  1. Remove heater return pipe. Refer to «PIPE - HEATER - RETURN»(ref-207938-S14704384362005120400000) .
  2. Release clip securing heater feed hose to heater feed pipe and disconnect hose from pipe.
  3. Remove nut securing heater feed pipe to plenum chamber.
  4. Press quick release connector and release heater feed pipe from plenum chamber.
  5. Remove and discard 'O' ring from pipe.
  1. Fit new 'O' ring to heater feed pipe and lubricate with castor oil.
  2. Secure heater feed pipe to plenum chamber.
  3. Fit and tighten nut securing heater feed pipe to plenum chamber.
  4. Connect heater feed hose to heater feed pipe and secure with clip.
  5. Fit heater return pipe. Refer to «PIPE - HEATER - RETURN»(ref-207938-S14704384362005120400000) .

Scheme 49

Scheme 49: Remove
Scheme 49: Remove

Scheme 50

Scheme 50
Scheme 50
  1. Drain engine coolant. Refer to «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .
  2. Release clip securing heater return hose to heater return pipe and disconnect hose from pipe.
  3. Remove bolt securing heater return pipe to heater feed pipe.
  4. Release clips securing engine harness and vacuum pipe to heater return pipe.
  5. Remove bolt securing heater return pipe to cylinder head.
  6. Release clip securing engine coolant hose to heater return pipe.
  7. Release engine coolant hose from heater return pipe and collect pipe.
  1. Connect engine coolant hose to heater return pipe and secure with clip.
  2. Position heater return pipe to cylinder block and secure with bolt.
  3. Secure engine harness and vacuum pipe to heater return pipe and secure with clips.
  4. Fit and tighten bolt securing heater return pipe to heater feed pipe.
  5. Connect heater return hose to heater return pipe and secure with clip.
  6. Refill engine coolant. Refer to «DRAINING & REFILLING COOLING SYSTEM»(ref-139295-S42055824182004100500000) .

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Scheme 51: Remove
Scheme 51: Remove

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Scheme 53
  1. Release fixings and remove battery cover.
  2. Disconnect battery earth lead.
  3. Clamp feed and return coolant hoses at FBH.
  4. Position container to collect spillage.
  5. Release clips, disconnect coolant feed and return hoses from FBH. CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.
  6. Disconnect 2 multiplugs from FBH.
  7. Position container to collect spillage and disconnect quick release fuel pipe from FBH. CAUTION: Before disconnecting any part of the fuel system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.
  8. Remove Torx bolt securing FBH to bulkhead mounting bracket.
  9. Release and remove FBH.
  10. Collect locating bushes from pegs.
  1. Fit bushes to pegs.
  2. Align FBH to pegs, fit Torx bolt and tighten to 25 Nm (18 lbf.ft).
  3. Clean quick release connection and fit fuel pipe to FBH.
  4. Connect multiplugs to FBH.
  5. Connect coolant hoses to FBH and secure with clips.
  6. Release clamps from hoses.
  7. Connect battery earth lead.
  8. Fit and secure battery cover.
  9. Top-up cooling system. Refer to «SERVICE»(ref-162012-S35533856072004051200000) .