Published: 11-May-2011

2007.0 Range Rover Sport (LS), 412-03D

Air Conditioning - TDV8 3.6L Diesel

Evaporator Core (G942471)

REMOVAL AND INSTALLATION
  • 82.25.20
  • Evaporator - Renew
  • TDV8
  • 7.70
  • USED WITHINS
Removal
  1. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  2. Remove the engine cover.
  3. Evacuate the air conditioning (A/C) system. For additional information, refer to: Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
  4. WARNING:

    Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

    Raise and support the vehicle.
  5. Partially drain the cooling system. For additional information, refer to: Cooling System Partial Draining, Filling and Bleeding (303-03E Engine Cooling - TDV8 3.6L Diesel, General Procedures).
  6. Remove the driver side front seat. For additional information, refer to: Front Seat (501-10, Removal and Installation).
  7. Remove the instrument panel upper section. For additional information, refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and Installation).
  8. E51208
    Release the 3 ground cables from the driver side lower A-pillar.
      • Remove the 2 nuts.
  9. E51209
    Disconnect the 5 electrical connectors from the driver side lower A-pillar.
  10. E51210
    Release the 3 ground cables from the passenger side lower A-pillar.
      • Remove the 2 nuts.
  11. Disconnect the heater motor electrical connector.
  12. E51211
    Disconnect the 5 electrical connectors from the passenger side lower A-pillar.
  13. E51212
    Disconnect the 2 central junction box (CJB) electrical connectors.
  14. Disconnect the 2 electrical connectors from the instrument panel center reinforcement.
  15. CAUTION:

    Cover fiber optic cable connectors to minimize dust ingress and avoid bending the cables in a radius of less than 30 mm.

    E51213
    If installed, disconnect the instrument panel center reinforcement fibre optic cables.
      • Disconnect the electrical connector.
  16. E52188
    Remove the heater housing center ducts.
  17. E49465
    Disconnect the steering column intermediate shaft from the steering column.
      • Note the fitted position.
      • Remove the special bolt and discard the nut.
  18. E52189
    Release the heater housing from the instrument panel carrier.
      • Remove the 7 screws.
  19. Remove the plenum chamber panel. For additional information, refer to: Plenum Chamber (412-01 Air Distribution and Filtering, Removal and Installation).
  20. E51204
    Remove the instrument panel carrier to bulkhead bolt.
  21. E52190
    With assistance, remove the instrument panel.
      • Remove the 6 bolts.
  22. CAUTION:

    Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

    E51205
    Disconnect 2 heater hoses from the bulkhead.
      • Release the 2 clips.
  23. Release the 2 A/C lines from the body.
      • Remove the nut.
  24. CAUTION:

    Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.

    E51206
    Release the 2 A/C lines from the bulkhead.
      • Remove the bolt.
      • Remove and discard the O-ring seals.
  25. E51207
    Remove the 2 adapter panels.
      • Remove the 4 nuts.
  26. E51199
    Disconnect the 2 drain tubes from the heater housing.
  27. E52191
    Remove the driver side footwell duct.
      • Remove the 2 Torx screws.
  28. E52192
    Remove the passenger side footwell duct.
      • Remove the 2 Torx screws.
  29. E52193
    Driver side: Remove the heater housing to bulkhead Torx bolt.
  30. E52194
    Passenger side: Remove the heater housing to bulkhead Torx bolt.
  31. Remove the heater housing.
  32. Disconnect the evaporator core temperature sensor electrical connector.
  33. E52196
    Release the heater core housing.
      • Remove the 2 screws.
      • Remove the 8 clips.
  34. E52197
    Remove the evaporator core.
      • Release the temperature sensor.
Installation
  1. Install the evaporator core.
      • Secure the temperature sensor.
  2. Secure the heater core housing.
      • Install the clips.
      • Tighten the screws.
  3. Connect the temperature sensor electrical connector.
  4. Install the heater housing.
  5. Passenger side: Install the heater housing to bulkhead bolt and tighten to 6 Nm (4 lb.ft).
  6. Driver side: Install the heater housing to bulkhead bolt and tighten to 6 Nm (4 lb.ft).
  7. Install the footwell ducts.
      • Tighten the screws.
  8. Connect the drain tubes to the heater housing.
  9. Install the adapter panels.
      • Tighten the nuts to 6 Nm (4 lb.ft).
  10. Secure the A/C lines to the bulkhead.
      • Clean the components.
      • Install new O-ring seals.
      • Tighten the bolt to 6 Nm (4 lb.ft).
  11. Secure the A/C lines to the body.
      • Tighten the nut to 6 Nm (4 lb.ft).
  12. Connect the bulkhead heater hoses.
  13. With assistance, install the instrument panel.
      • Tighten the bolts to 25 Nm (18 lb.ft).
  14. Install the instrument panel carrier to bulkhead bolt and tighten to 25 Nm (18 lb.ft).
  15. Install the plenum chamber panel. For additional information, refer to: Plenum Chamber (412-01 Air Distribution and Filtering, Removal and Installation).
  16. Secure the heater housing.
      • Tighten the screws.
  17. Connect the steering column intermediate shaft.
      • Install the special bolt and tighten the new nut to 22 Nm (16 lb.ft).
  18. Install the heater housing center ducts.
  19. Connect the instrument panel center reinforcement fibre optic cables.
  20. Connect the instrument panel center reinforcement electrical connectors.
  21. Connect the CJB electrical connectors.
  22. Connect the heater motor electrical connector.
  23. Connect the electrical connectors to the passenger side lower A-pillar.
  24. Connect the ground cables to the passenger side lower A-pillar.
      • Tighten the nuts to 10 Nm (7 lb.ft).
  25. Connect the electrical connectors to the driver side lower A-pillar.
  26. Connect the ground cables to the driver side lower A-pillar.
      • Tighten the nuts to 10 Nm (7 lb.ft).
  27. Install the instrument panel upper section. For additional information, refer to: Instrument Panel Upper Section (501-12 Instrument Panel and Console, Removal and Installation).
  28. Install the front seat. For additional information, refer to: Front Seat (501-10, Removal and Installation).
  29. Recharge the A/C system. For additional information, refer to: Air Conditioning System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
  30. Install the engine cover.
  31. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  32. Fill and bleed the cooling system. For additional information, refer to: Cooling System Partial Draining, Filling and Bleeding (303-03E Engine Cooling - TDV8 3.6L Diesel, General Procedures).