Ideas how to fix leaking air conditioner?

[Dan]

Can anyone help?
My 2000 TD5 Defender had an airconditioner fitted by the dealer when new.
It works well, even in the middle of the Nullabor in summer, but it leaks into the cabin on the passenger side. Switch it on and soon enough water builds up inside the unit and sloshes around, then starts leaking out.
I checked previous threads about Deefa airconditioning and found one in 2007 on this same topic. Seems some other owners had this problem but no one was able to suggest the cause or solve the problem.
The puddle on the floor wouldn't be such a problem but my better half puts her handbag there!
Before I pull out the aircondioner, does anyone have any idea what might be causing this problem? Or does anyone have a diagram of the unit's internals? Has anyone had this problem and been able to fix it?
I have cleared the drain tubes and blown compressed air through the system but although some water drains through the tubes, the unit still pools water and leaks.
If possible I'd rather know what to expect before I pull the dash apart, drill out the rivets and remove the unit. Cheers.

[Scouse]

Is it the evaporator drain tubes that you cleared? It certainly sounds like the evaporator drain is blocked.
If it's not blocked, then the casingitself might be cracked or split.

[bosvit]

Have you run it with the bottom cover off to see where the leak comes from.

If you slide a sheet of white paper underneath the unit before you turn it on you will quickly see where it is dripping from.

My guess is that you either have a crack or small hole in the housing or one of your hoses has perished. Either way a fairly simple repair.

[Dan]

Thanks guys.
Yes bosvit, I've had the bottom cover off and have removed and cleaned the two hoses that join up underneath and exit under the car.
Could be a broken housing Scouse - maybe somewhere I can't see from the front - but what's got me foxed is that the two drain hoses connect on each side of the bottom of the unit at its lowest point. If they are not blocked, and if the part they join is not blocked, I can't work out how water can pool unless there is another compartment inside the unit that is blocked.
The water leaks somewhere above or around the fan blades and when the water builds up you can hear a sound like the fan blades skimming water.
I'd love to see a diagram of the guts of this system before I attempt surgery.
Cheers, Dan

[Scouse]

I'd love to see a diagram of the guts of this system before I attempt surgery.
I don't like your chances of that unfortunately. Up to 2002, it was a local A/C unit fitted to Australian Defenders, not a UK unit. The manufacturer (AMC) is no longer around.


Maybe a hook to keep the handbag off the floor might be a cheaper option ;). It's not as if the door seals will let it pool too deeply :(.

[Only ever owned landys Ed]

I've got the same problem. Did you find out what was going wrong

[Don 130]

That machine was originally designed to operate in a horizontal position. Because of the acute angle of it's fitment , the drains are in the wrong position. The water drains down all the way into the fan housing where the fan makes a splashing noise as it sloshes the water out over the edge of the fan housing. So you need to VERY CAREFULLY drill into the outside bottom dead centre of the fan housing, being careful not to hit the fan with the drill.Then you need to fit over the holes, someting that will allow a piece of plastic tubing to fit onto. (I used chopped off barbs from aquarium fittings ,stuck on with megapoxy)I reckon about 10 mm hose over about a 6mm ID barb because anything smaller will not drain I know this because I've done it and my hose size is too small and I need to redo it. Join the two new drain tubes together with a 'y' and send a single one through the floor. Regards Don

[Ryhoon]

my 99 130 does the same. it sounds like it might be icing up inside and blocking up the pipes on mine. yet to have a better look though.

[BilboBoggles]

That machine was originally designed to operate in a horizontal position. Because of the acute angle of it's fitment , the drains are in the wrong position. The water drains down all the way into the fan housing where the fan makes a splashing noise as it sloshes the water out over the edge of the fan housing. So you need to VERY CAREFULLY drill into the outside bottom dead centre of the fan housing, being careful not to hit the fan with the drill.Then you need to fit over the holes, someting that will allow a piece of plastic tubing to fit onto. (I used chopped off barbs from aquarium fittings ,stuck on with megapoxy)I reckon about 10 mm hose over about a 6mm ID barb because anything smaller will not drain I know this because I've done it and my hose size is too small and I need to redo it. Join the two new drain tubes together with a 'y' and send a single one through the floor. Regards Don

This is exactly what Land Rover did as a Warranty Fix on my MY03 TD5 A/C. Same issue, the drain is in the wrong place. (This was a factory Air unit not the local fitted one.)

I now have TWO drain tubes, but at least no leak since 2003 when the mod was done.

[Yorkshire_Jon]

This is exactly what Land Rover did as a Warranty Fix on my MY03 TD5 A/C. Same issue, the drain is in the wrong place. (This was a factory Air unit not the local fitted one.)

I now have TWO drain tubes, but at least no leak since 2003 when the mod was done.

Any chance of any photos with the mod in place. I realize this may invoke removing the plastic cover to show where to drill but everyone with a TD5 Defer will appreciate it!!!

Thx
Jon

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[blackapache]

This is exactly what Land Rover did as a Warranty Fix on my MY03 TD5 A/C. Same issue, the drain is in the wrong place. (This was a factory Air unit not the local fitted one.)

I now have TWO drain tubes, but at least no leak since 2003 when the mod was done.

yeah second that it would be great to see a pic or two if you get time, this is on my shortlist of fixes this month.

cheers