cooling LAND ROVER DISCOVERY 1995 Repair Manual

26COOLING SYSTEM
4
REPAIR THERMOSTATIC SENSOR
Service repair no - 19.22.18
Remove
1.Disconnect Lucar connector from sensor.
2.Remove sensor.
Refit
3.Clean sensor.
4.Apply Loctite 405 to threads of sensor.
5.Fit sensor and tighten to
15Nm
6.Connect Lucar to sensor.
7.Top-up cooling system.THERMOSTAT
Service repair no - 26.45.01
Remove
1.Position suitable container to collect coolant.
2.Slacken 2 clips and release radiator top hose.
3.Release bypass hose from securing bracket.
4.Release top hose from securing bracket.
5.Remove top hose.

Mpi
5
REPAIR 6.Remove clip securing thermostat in hose.
7.Lubricate hose in front of thermostat and
manoeuvre thermostat from hose.
Refit
8.Lubricate inside of top hose with liquid soap.
9.Manoeuvre thermostat into hose to previous
position.
10.Fit and tighten clip securing thermostat to top
hose.
11.Refit radiator hose.
12.Top-up cooling system.

ZF
5
REPAIR Remove
1.Select low range with transfer gear lever.
2.Remove knob and gaiter from transfer gear
lever.
3.Disconnect battery terminals.
4.Remove insulation pad from rocker cover and
inlet manifold.
5.On LH drive vehicles only, disconnect multi-plug
from top of brake fluid reservoir.
6.Release electrical harness from clips along top
of bulkhead and pull over to one side.7.Remove bolt securing transfer and main gearbox
breather pipe clip to rear of cylinder head.
8.Disconnect kick down cable at fuel injection
pump.
9.Drain coolant from cooling system.
10.Disconnect top hose from radiator.
11.Disconnect turbo charger hose from inter-cooler.
12.Remove starter heat shield.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

57STEERING
6
REPAIR Refit
6.Position reservoir, connect feed and return
hoses and tighten clamps to
3 Nm.
7.Fit reservoir in clamp, tighten clamp bolt.
8.Fill reservoir to 'MAX' mark on dipstick with
power steering fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
9.Fit undertray.
10.Bleed power steering system.
See Power
Steering System - Bleed
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.02
NOTE: For details of drive belt remove and
refit.
See ENGINE, Repair, Drive Belt
POWER STEERING PUMP - V8i
Service repair no - 57.20.14
NOTE: The power steering pump is not
serviceable. Fit new pump if worn or
damaged.
Remove
1.Disconnect battery negative lead.
2.Remove drive belt from steering pump.
See
ENGINE, Repair, Drive Belt
3.Remove undertray.
4.Remove fan blades and viscous coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
5.Position drain tin beneath steering pump.
6.Using a 9 mm Allen key to restrain steering
pump pulley, remove 3 bolts securing pulley to
pump; remove pulley.

STEERING
7
REPAIR 7.Loosen clamp securing reservoir hose to
steering pump; disconnect hose.
8.Disconnect high pressure pipe from steering
pump.
CAUTION: Plug the connections.
9.Release ht lead from clip
10.Remove 3 bolts securing steering pump.
Remove pump and recover engine lifting
bracket.
NOTE:Do not carry out further
dismantling if component is removed for
access only.
11.Remove 5 bolts securing front mounting plate.
12.Fit front mounting plate to replacement steering
pump. Tighten bolts to
9 Nm.
Refit
13.Position steering pump and engine lifting plate,
fit bolts. Tighten to
35 Nm.Secure ht lead in
clip.
14.Connect high pressure pipe to steering pump,
tighten union to
20 Nm.
15.Connect reservoir hose to steering pump.
Tighten clamp to
3 Nm.
16.Position pulley to pump, coat threads of bolts
with Loctite 242.
17.Restrain pulley using a 9 mm Allen key, fit bolts.
Tighten to
10 Nm.
18.Fit drive belt.See ENGINE, Repair, Drive Belt
19.Fit fan blades and viscous coupling.See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
20.Fit undertray.
21.Reconnect battery negative lead.
22.Bleed power steering system.
See Power
Steering System - Bleed
POWER STEERING PUMP - Tdi
Service repair no - 57.20.14
Remove
1.Remove fan blades and viscous coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
2.Restrain steering pump pulley, loosen but do not
remove 3 bolts securing pulley.
3.Remove drive belt.
See ENGINE, Repair,
Drive Belt
4.Remove 3 bolts securing steering pump pulley,
remove pulley.
5.Remove undertray.
6.Position drain tin beneath steering pump.

57STEERING
8
REPAIR 7.Loosen clamp securing reservoir hose to
steering pump, disconnect hose.
8.Disconnect high pressure pipe from steering
pump.
CAUTION: Plug the connections.
9.Remove 4 bolts securing steering pump to
mounting bracket, remove pump.
NOTE:Do not carry out further
dismantling if component is removed for
access only.
10.Remove 3 bolts securing mounting plate to
pump, remove plate.
11.Fit mounting plate to replacement steering
pump. Tighten bolts to
9 Nm.
Refit
12.Position steering pump, fit 3 bolts. Tighten to
35
Nm.
13.Connect high pressure pipe to steering pump.
Tighten to
20 Nm.
14.Connect reservoir hose to steering pump.
Tighten clamp to
3 Nm.
15.Position pulley to steering pump, coat threads of
bolts with Loctite 242; fit but do not fully tighten 3
bolts.
16.Fit drive belt.
See ENGINE, Repair, Drive Belt
17.Restrain steering pump pulley, tighten bolts to10
Nm.
18.Fit fan blades and viscous coupling.See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
19.Fit undertray.
20.Bleed power steering system.
See Power
Steering System - Bleed

HEATING AND VENTILATION
3
DESCRIPTION AND OPERATION
Controls set for unheated air to footwells and face level vents
Heater and ventilation operation
The heating and ventilation system contains a heater
matrix, which is connected to the engine cooling
system, and a 4 speed fan for air distribution. Engine
coolant is circulated through the heater matrix
continuously, except when the temperature controls
are set to COLD.
Recirculated air
When the recirculation switch is pressed, an electrical
servo operates and fully closes the fresh air intake
flap.
Fresh air
When the recirculation switch is returned to the OFF
position, the electrical servo returns and fully opens
the fresh air intake flap.Heated air
Temperature output is controlled by the temperature
controls which move the air direction and temperature
flaps independently to increase or decrease the
volume of air flow through the heater matrix.
V8 Engine:When both controls are in the cold
position, the coolant valve is turned off.
Face level vent flap
Control at face level, flap fully open. All other vents
closed.
Control at face and foot level, flaps half open.
Unless an air conditioning unit is fitted, only fresh or
re-circulated air is available from the face level vents.
Demist vent flap
Control at demist, flap fully open. All other vents
closed.
Control at demist and foot level, flaps half open.

HEATING AND VENTILATION
1
FAULT DIAGNOSIS HEATER OUTPUT
Symptom:-
Heater emits cold air.
1.Engine running: Check coolant valve opens as a
temperature control is moved from COLD.
2.Check for engine running cold.
See COOLING
SYSTEM, Fault diagnosis, Engine Runs Cold
3.Check heater pipes and hoses for blockage or
restriction.
4.Check heater matrix for blockage or restriction,
flush system.
Heater emits warm air.
5. Engine running:Check coolant valve closes
when both temperature controls are moved to
COLD.

82AIR CONDITIONING
2
DESCRIPTION AND OPERATION SCHEMATIC LAYOUT OF THE AIR CONDITIONING
SYSTEM
1. Compressor
2. Condenser
3. Receiver/drier
4. Thermostatic expansion valve
5. Evaporator
6. Capillary tube
7. Dual pressure switch
8. Cooling fans to maintain air flow
9. Compressor high pressure relief valve
10. Sight glass - refrigerant
11. Drying agent - receiver/drier
12. Blower motorA1 Ambient air flow through condenser
A2 Ambient air flow through fan and evaporator
A3 Cooled air flow to vehicle interior
F1 High pressure high temperature refrigerant
vapour
F2 High pressure slightly subcooled refrigerant
liquid
F3 High pressure slightly subcooled refrigerant
liquid with moisture, vapour bubbles and foreign
matter removed
F4 Low pressure low temperature mixed liquid and
vapour
F5 Low pressure slightly super heated refrigerant
vapour