Refit Land Rover Discovery L319

Refit

1. Calculate the quantity of refrigerant oil required. Refer to «AIR CONDITIONING COMPRESSOR REPLACEMENT»(ref-170191-S19576176402005010700000) .
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.
10. Fit auxiliary drive belt.
11. Recharge air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
12. Fit engine acoustic cover.

Scheme 18

1. De-pressurize air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
2. Remove auxiliary drive belt.
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.

1. Calculate the quantity of refrigerant oil required. Refer to «AIR CONDITIONING COMPRESSOR REPLACEMENT»(ref-170191-S19576176402005010700000) .
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. Refer to «DRIVE BELT ROUTING»(ref-139295-S20370064032004100500000) .
10. Recharge air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .

Scheme 19

1. Remove front grille. Refer to «REMOVE»(ref-207934-S31877035392005120400000) .
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.

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. Refer to «REFIT»(ref-207934-S11530763662005120400000) .

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1. Recover refrigerant from A/C system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
2. Remove 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.
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.
18. Remove sealing strip from outer upper seam of condenser.
19. Remove captive nut plates from condenser.

1. Fit captive nut plates to new condenser.
2. Fit seal to condenser.
3. Fit RH mounting bracket to condenser and secure with bolt.
4. Fit receiver drier bracket assembly and secure with bolts.
5. Ensure condenser pipe and new receiver drier connections are clean.
6. Lubricate new 'O' ring with refrigerant oil and fit to condenser pipe.
7. Fit receiver drier to bracket and condenser pipe. Tighten bolt securing condenser pipe to 5 Nm (3.7 lbf.ft). Fit clamping bolt securing receiver drier to bracket and tighten to 5 Nm (3.7 lbf.ft).
8. Ensure adaptor block and receiver drier connections are clean.
9. Lubricate new 'O' ring with refrigerant oil and fit to adaptor block.
10. Fit adaptor block to receiver drier and tighten bolt to 5 Nm. (3.7 lbf.ft).
11. Fit condenser assembly.
12. Fit cooling fan to condenser and fit bolts to secure support rails to condenser brackets.
13. Ensure connections of condenser, receiver drier and evaporator pipes are clean.
14. Lubricate new 'O' ring seals with refrigerant oil and fit one seal to each evaporator pipe.
15. Connect evaporator pipes and tighten bolts to 5 Nm (3.7 lbf.ft).
16. Connect multiplug to dual pressure switch.
17. Fit radiator.
18. Recharge A/C system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .

Scheme 25

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Scheme 27

1. Recover refrigerant from air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
2. Remove front grille. Refer to «REMOVE»(ref-207934-S31877035392005120400000) .
3. Disconnect multiplug from dual pressure switch.
4. Remove bolt securing condenser pipe to receiver drier.
5. Disconnect condenser pipe from receiver drier. CAUTION: Always fit plugs to open connections to prevent contamination.
6. Remove bolt securing evaporator pipe to receiver drier.
7. Disconnect evaporator pipe from receiver drier. CAUTION: Always fit plugs to open connections to prevent contamination.
8. Remove bolt securing top of receiver drier mounting bracket to condenser.
9. Remove bolt securing bottom of receiver drier mounting bracket to condenser.
10. Remove receiver drier assembly.
11. Loosen mounting bracket clamping bolt.
12. Remove receiver drier from mounting bracket.
13. Remove dual pressure switch from receiver drier

1. Fit dual pressure switch to receiver drier and tighten to 10 Nm (7 lbf.ft).
2. Fit receiver drier to mounting bracket and tighten clamping bolt.
3. Fit receiver drier assembly to condenser.
4. Fit bolts securing receiver drier mounting bracket to condenser and tighten to 5 Nm (3.7 lbf.ft).
5. Remove caps from air conditioning pipes and receiver drier.
6. Remove old 'O' rings from pipes.
7. Fit new 'O' rings to pipes and lubricate with refrigerant oil.
8. Connect air conditioning pipes to receiver drier.
9. Fit bolts securing air conditioning pipes to receiver drier and tighten to 5 Nm (3.7 lbf.ft).
10. Connect multiplug to dual pressure switch.
11. Fit front grille. Refer to «REFIT»(ref-207934-S11530763662005120400000) .
12. Recharge air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .

Scheme 28

1. Release radio from fascia. Refer to «REMOVE»(ref-208281-S26803837802005120500000) .
2. Working through radio aperture, release control unit from fascia.
3. Disconnect 3 multiplugs and remove control unit.
4. Collect bushes from control unit location pegs.

1. Fit bushes to new control unit.
2. Position control unit and connect multiplugs.
3. Fit control unit to fascia.
4. Fit radio to fascia. Refer to «REFIT»(ref-208281-S36046234172005120500000) .

Scheme 29

1. Remove front grille. Refer to «REMOVE»(ref-207934-S31877035392005120400000) .
2. Release ambient air temperature sensor from support bracket, disconnect multiplug and remove sensor.

1. Position sensor, connect multiplug and secure sensor to support bracket
2. Fit front grille. Refer to «REFIT»(ref-207934-S11530763662005120400000) .

Scheme 30

1. Carefully remove solar light sensor from fascia.
2. Disconnect multiplug from solar light sensor.
3. Remove solar light sensor.

1. Connect multiplug to solar light sensor.
2. Position solar light sensor to fascia and push to secure.

Scheme 31

Scheme 32

1. Release 2 quarter turn screws to release fascia access panel.
2. Lower fascia access panel.
3. Disconnect multiplug from air temperature sensor.
4. Remove 2 screws securing air temperature sensor to fascia.
5. Remove air temperature sensor from fascia.

1. Position air temperature sensor to fascia and secure with screws.
2. Connect multiplug to air temperature
3. Position and secure fascia access panel with quarter turn screws.

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Scheme 41

1. Remove heater assembly. Refer to «REMOVE»(ref-207938-S18417605322005120400000) .
2. Remove bulkhead and evaporator pipe seals.
3. Disconnect multiplug from evaporator thermistor.
4. Remove 2 screws securing temperature control servos to evaporator casing.
5. Remove 2 screws securing coolant pipe support bracket to casing.
6. Remove screws securing coolant pipe saddle clamp to casing and remove saddle.
7. Remove heater matrix.
8. Remove 5 screws securing casings.
9. Remove 12 spring clips securing casings.
10. Remove evaporator casing and collect insulation.
11. Remove evaporator assembly.
12. Remove evaporator thermistor.
13. Remove covering from TX valve, release 2 clips securing TX valve to pipe.
14. Release 2 unions securing TX valve, remove TX valve, remove and discard 'O' rings.
15. Release pipe union, remove pipe and discard 'O' ring.

1. Using a new 'O' ring, position pipe to evaporator and tighten union.
2. Using new 'O' rings, position TX valve. Connect pressure pipe union and tighten to 22 Nm (16 lbf. ft). Connect evaporator pipe and tighten to 32 Nm (24 lbf.ft).
3. Position TX valve sensor to pipe and secure with clips.
4. Fit sensor covering.
5. Fit evaporator thermistor.
6. Fit evaporator assembly.
7. Fit insulation to evaporator casing and fit casing.
8. Secure spring clips.
9. Fit and tighten casing screws.
10. Fit heater matrix, ensuring matrix temperature is correctly positioned.
11. Fit coolant pipe saddle, fit and tighten screws securing saddle and pipe bracket.
12. Fit and tighten temperature servo screws.
13. Connect multiplug to evaporator thermistor.
14. Clean any bulk head seal from casing.
15. Fit bulkhead and evaporator pipe seals.
16. Fit heater assembly. Refer to «REFIT»(ref-207938-S13941258682005120400000) .

Scheme 42

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Scheme 44

1. De-pressurize air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
2. Remove rear lower trim casing. Refer to «REMOVE»(ref-207935-S41768256702005120400000) .
3. Remove 5 bolts securing seat support bracket and remove bracket.
4. Release insulation from TXV pipe unions and sensor.
5. Remove clip securing sensor to pipe and release sensor.
6. Loosen TXV pipe unions, release pipes and remove TXV.
7. Remove and discard 'O' rings.

1. Lubricate new 'O' rings with clean refrigerant oil and fit to TXV pipes.
2. Position TXV, align pipes and tighten unions.
3. Connect sensor and secure with clip.
4. Fit insulation to TXV valve and sensor.
5. Position seat support bracket, fit bolts and tighten to 24 Nm (18 lbf.ft)
6. Repressurize air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
7. Fit rear lower trim casing. Refer to «REFIT»(ref-207935-S21366526752005120400000) .

Scheme 45

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Scheme 48

1. Remove evaporator assembly. Refer to «EVAPORATOR AND MOTOR ASSEMBLY - REAR»(ref-207939-S04756321362005120400000) .
2. Remove insulation from TXV.
3. Release relay from support bracket.
4. Remove ducting seal.
5. Remove 4 screws securing lower part of casing, release and remove lower casing.
6. Remove 6 screws and 4 clips securing main casing and remove top half of casing.
7. Loosen and release evaporator pipes unions, release pipes and remove evaporator.
8. Remove and discard evaporator pipe 'O' rings.

1. Lubricate new 'O' rings with clean refrigerant oil and fit to evaporator pipes
2. Position evaporator, connect pipes and tighten unions.
3. Position main casing and secure with clips and screws.
4. Position lower part of casing and secure with screws.
5. Fit ducting seal
6. Secure relay to support bracket.
7. Fit insulation to TXV.
8. Fit evaporator assembly. Refer to «EVAPORATOR AND MOTOR ASSEMBLY - REAR»(ref-207939-S04756321362005120400000) .

Scheme 49

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Scheme 53

1. De-pressurize air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .
2. V8 models: Remove 4 clips securing rear exhaust heat shield and remove heat shield.
3. Remove 2 bolts securing high and low pressure pipes, release pipes and discard 'O' rings. CAUTION: Always fit plugs to open connections to prevent contamination.
4. Remove 2 bolts securing grommet flange to body and remove flange.
5. Remove LH rear lower trim casing. Refer to «REMOVE»(ref-207935-S41768256702005120400000) .
6. Remove 5 bolts securing seat support bracket and remove bracket.
7. Disconnect A/C harness multiplugs from body harness.
8. Remove 2 clips securing ducting to A/C assembly and release ducting.
9. Remove 4 bolts securing evaporator assembly and remove assembly.

1. Position evaporator assembly to body fit bolts and tighten to 16 Nm (12 lbf.ft).
2. Position ducting to evaporator assembly and secure with clips.
3. Connect harness multiplugs.
4. Position seat support bracket, fit bolts and tighten to 24 Nm (18 lbf.ft).
5. Fit LH rear lower trim casing. Refer to «REFIT»(ref-207935-S21366526752005120400000) .
6. Position grommet flange and tighten bolts.
7. Lubricate new 'O' rings with clean refrigerant oil and fit to high and low pressure pipes.
8. Position high and low pressure pipes, fit bolts and tighten to 10 Nm (7 lbf.ft).
9. V8 models: Position exhaust heat shield and secure with clips.
10. Repressurize air conditioning system. Refer to «REFRIGERANT RECOVERY, RECYCLING AND RECHARGING»(ref-207939-S04214805682005120400000) .

Scheme 54

Scheme 55

1. Remove rear lower trim casing. Refer to «REMOVE»(ref-207935-S41768256702005120400000) .
2. Remove 5 bolts securing third row seat support bracket and remove bracket.
3. Disconnect blower motor multiplug and release hose from casing.
4. Remove screws securing blower motor and remove motor from casing.

1. Position motor, align to casing and secure with screws.
2. Connect motor multiplug and secure hose to casing.
3. Position seat support bracket, fit bolts and tighten to 24 Nm (18 lbf.ft)
4. Fit rear lower trim casing. Refer to «REFIT»(ref-207935-S21366526752005120400000) .

Scheme 56

1. Remove rear lower trim casing. Refer to «REMOVE»(ref-207935-S41768256702005120400000) .
2. Disconnect resistor multiplug.
3. Remove 2 screws securing resistor pack to casing. Remove resistor from casing.

1. Position resistor and secure with screws.
2. Connect resistor multiplug.
3. Fit rear lower trim casing. Refer to «REFIT»(ref-207935-S21366526752005120400000) .

Scheme 57

1. Remove headlining. Refer to «REMOVE»(ref-207935-S16115551172005120400000) .
2. Drill out 4 rivets securing center duct to roof.
3. Release center duct from upper side duct and remove.
4. Drill out 2 rivets securing mounting braces to duct.
5. Remove braces.

1. Position braces to duct and secure with rivets.
2. Fit center duct between upper side ducts.
3. Fit rivets securing center duct to roof.
4. Fit headlining. Refer to «REFIT»(ref-207935-S42238039992005120400000) .