Thread: Summer is here, and aircon is not ....

'02 TD5 Defender

I'm not particularly mechanically minded, but can follow instructions and have a healthy serve of cdf ... and don't mind working through and getting my hands dirty ... until it starts costing more money doing it myself ....

When I turn on the aircon, the fuse for the aircon compressor relay/electric fan relay (fuse 29) blows - jeez they don't half spark up ...

- switched out relays (1 & 2 underseat box) - fuse blows
- disconnected electric fan - fuse blows
- disconnected compressor - fuse OK
- 13.7v delivered to plug at compressor
- measured resistance across compressor connections at socket - 4.6 ohm (I've got a Densco; can't find any service info, 2.8 - 4.4 spec for the Sanden from their service manual)

Seems to me that if there was a bad earth or short in the wiring, the fuse would blow even if the compressor was disconnected. Can anyone help diagnosing the problem? The easiest solution in that the compressor is causing the short, but don't know how to test that any further?

Otherwise does anyone know a good A/C place in Perth? NOR.

cheers

I would rework the plug using a flylead type plug that comes prewired. Heres how I would rejoin it. (this assumes you have the 2 wire connector half it if you only have the single)

GEAR needed
2 exposed type inline crimp connector for double the wire size you have to join
4 lengths of heatshrink just over the size of the insulation of the wire about 1cm long
2 lengths of heatshrink just bigger than the connector in diameter and about 1cm longer than the connector itself
1 length of heatshrink bigger than the 2 connectors side by side
sealastic and about 3cm longer than the connector

Heres how to do it.
Slide the 4 pieces of small heatshrink up the individual wires on the flylead connector
slide the joiners up onto the wires of the connector and over the heat shrink
Slide the intermediate diameter heatshrink up onto the wires that dont have the connectors on them
Slide the largest piece of heatshrink over both of those wires.
Strip back the wires just short of the same length of the joiner and DONT twist them.
press the 2 ends of the wire together, get it right and you should wind up with all the strands parallel and the wire essentially double in diameter.
slide the connector down over the joint, push the 2 wires together and very very lightly crimp the exact middle of the joiner with a cheap crimping tool, just enough to hold the wires in place.
Slide the 4 smallest pieces of heatshrink back towards the connector and just under the connector then complete the crimp with the appropriate connection
shrink the first 4 pieces of heat shrink
Slide the intermediate pieces of heatsrhink up over the crimps and shrink them
Slide the large piece over the connectors and dont shrink it
Inject silicone into the heatshrink till it comes out the other side
shrink the large piece of heatshrink
Clean up the mess.

Done, never to cause a problem again.