cooling system - v8 LAND ROVER DISCOVERY 1999 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 1999, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 1999Pages: 1529, PDF Size: 34.8 MB
Page 797 of 1529
FRONT SUSPENSION
60-52 REPAIRS
Pipe assembly - pump or reservoir to
valve block - ACE - V8
$% 60.60.32
Introduction
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.To avoid any possibility of swarf ingress,
remove the valve block.
+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
2.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Remove RH front road wheel.
4.Remove 3 screws and remove splash shield.
5.Remove viscous fan.
+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.6.Remove 2 screws securing lower fan cowl and
remove cowl.
7.Disconnect multiplug from MAF sensor.
Note: Pre 03 MY air intake hose illustrated.
8.Release clips and remove air flow meter from
air cleaner.
9.Collect 'O' ring.
Page 799 of 1529
FRONT SUSPENSION
60-54 REPAIRS
16.Remove bolt securing pipe clamp to RH
chassis member and remove clamp.
17.Release harness clip from RH suspension
turret.
18.Remove nut securing pipe clamp to bracket on
RH suspension turret and remove clamp.
19.Release pipe from isolator above chassis RH
front outrigger.
20.Cut pipe at suitable point near suspension
turret.
21.Remove and discard front and rear sections of
pipe. Refit
1.Fit both sections of new pipe to vehicle.
2.Ensure 'O' ring is fitted to union on front section
of pipe.
3.Push both sections ofpipe together squarely
and tighten union nut to 16 Nm (12 lbf.ft).
4.Locate pipe in isolator above chassis RH front
outrigger. Fit cable tie around isolator to secure
pipe.
5. Valve block to reservoir pipe:Fit clip to
reservoir hose, connect hose to reservoir and
secure with clip.
6. Pump to valve block pipe: Ensure pipe banjo
and ACE pump connections are clean, fit new
sealing washers, align banjo to pump and
tighten bolt to 29 Nm (21 lbf.ft).
7.Fit pipe clamps to pipe, align clamps to front
cross member and fit bolts.
8. Valve block to reservoir pipe: Fit pipe to clip
on LH chassis member.
9.Fit pipe clamp to pipes, align clamp to
suspension turret and secure with nut.
10.Fit pipe clamp to pipes, align clamp to RH
chassis member and secure with bolt.
11.Align and secure harness to suspension turret.
12.Fit 'O' ring to air cleaner.
13.Fit air hose to throttle body and secure with clip.
14.Fit air flow meter and secure with clips.
15.Connect multiplug to MAF sensor.
16.Fit lower fan cowl and secure with screws.
17.Fit viscous fan.
+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
18.Fit RH splash shield and secure with screws.
19.Fit road wheel(s).
20.Fit valve block.
+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
21.Renew ACE high pressure filter.
22.Lower vehicle.
Page 800 of 1529
FRONT SUSPENSION
REPAIRS 60-55
Pipe assembly - pump or reservoir to
valve block - ACE - diesel
$% 60.60.32
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Remove
1.To avoid any possibility of swarf ingress,
remove valve block.
+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
2.Drain cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
3.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Remove RH front road wheel.
5.Remove 3 screws and remove splash shield.
6.Remove viscous fan.
+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.7.Remove 2 screws securing lower half of fan
cowl and remove cowl.
8.Disconnect multiplug from air flow meter.
9.Release clips and remove air flow meter from
air cleaner.
10.Collect 'O' ring.
Page 803 of 1529
FRONT SUSPENSION
60-58 REPAIRS
Refit
1.Fit both sections of new pipe to vehicle.
2.Ensure 'O' ring is fitted to union on front section
of pipe.
3.Push both sections of pipe together squarely
and tighten union nut to 16 Nm (12 lbf.ft).
4.Locate pipe in isolator above chassis RH front
outrigger. Fit cable tie around isolator to secure
pipe.
5. Valve block to reservoir pipe: Fit clip to
reservoir hose, connect hose to reservoir and
secure with clip.
6. Pump to valve block pipe: Ensure pipe banjo
and ACE pump connections are clean, fit new
sealing washers, align banjo to pump and
tighten bolt to 29 Nm (21 lbf.ft).
7.Fit pipe clamps to pipes, align clamps to
chassis front cross member and fit bolts.
8. Valve block to reservoir pipe: F it pi pe to c li p
on LH chassis member.
9.Fit pipe clamp to pipes, align clamp to
suspension turret and secure with nut.
10.Fit pipe clamp to pipes, align clamp to RH
chassis member and secure with bolt.
11.Align and secure harness to suspension turret.
12.Fit thermostat housing and hoses and secure
hoses with clips.
13.Fit turbocharger outlet pipe and secure hoses
with clips.
14.Connect turbocharger pressure sensing hose
and secure with clip.
15.Fit 'O' ring to air cleaner.
16.Fit air hose to turbocharger and tighten clip.
17.Fit air flow meter to air cleaner and secure with
clips.
18.Connect multiplug to air flow meter.
19.Fit lower half of fan cowl and secure with
screws.
20.Fit viscous fan.
+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
21.Fit RH splash shield and secure with screws.
22.Fit road wheel.23.Fit valve block.
+ FRONT SUSPENSION, REPAIRS,
Valve block - ACE.
24.Renew ACE high pressure filter
+ FRONT SUSPENSION, REPAIRS,
Filter - high pressure - ACE.
25.Lower vehicle.
26.Fill cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
Page 1179 of 1529
HEATING AND VENTILATION
80-22REPAIRS
Heater assembly - models without air
conditioning
$% 80.20.01.99
Remove
1.Drain cooling system.
l
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
l
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2. Diesel models: Remove 3 bolts and remove
engine cover.
3.Release clips and disconnect coolant hoses
from heater pipes.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove facia assembly.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.5.Disconnect harness multiplug from heater
blower motor.
6.Remove bolt and 2 nuts securing heater
blower housing assembly to body and remove
blower.
7.Disconnect 2 drain tubes from base of heater.
Page 1180 of 1529
HEATING AND VENTILATION
REPAIRS 80-23
8.Remove 2 screws securing console bracket to
tunnel and remove bracket.
9.Release radio coaxial cable from behind heater
pipes.
10.Protect the carpet from coolant spillage.
11.Remove 4 nuts and 1 bolt securing heater to
body.
12.Remove heater from vehicle.
13.Remove 2 screws securing heater RH and LH
footwell outlet duct to heater casing and
remove ducts. 14.Remove 2 screws securing matrix pipe bracket
to heater casing.
15.Remove screw securing pipe clamp to heater
casing and remove clamp.
16.Carefully remove matrix from heater.
Refit
1.Fit matrix into heater casing.
2.Fit screws securing pipe bracket to heater
casing.
3.Fit pipe clamp and secure with screw.
4.Fit heater ducts and secure with screws.
5.Position heater assembly to vehicle, ensure
heater coolant pipe grommet is correctly
located in bulkhead and secure with nuts and
bolt.
6.Fit radio coaxial cable behind heater pipes.
7.Fit console bracket and secure with screws.
8.Connect drain tubes to base of heater.
9.Fit blower unit to heater and secure to body
with nuts and bolt.
10.Connect harness multiplug to blower motor.
11.Fit facia assembly
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
12.Connect heater hoses and secure with clips.
13. Diesel models: Fit engine cover and secure
with bolts.
14.Refill cooling system
l
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
l
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
Page 1181 of 1529
HEATING AND VENTILATION
80-24REPAIRS
Heater assembly - models with air
conditioning
$% 80.20.01.98
Remove
1.Drain cooling system.
l
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
l
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Evacuate air conditioning system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3.Release 2 clips securing heater hoses to
heater and release hoses.
4.Remove 2 bolts securing air conditioning pipes
to evaporator, release pipes and discard 'O'
rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.6.Remove screws securing rear heater ducting
and remove ducting.
7.Disconnect multiplug from heater motor.
8.Remove 2 nuts and bolt securing heater motor
assembly and remove motor assembly from
heater casing.
Page 1182 of 1529
HEATING AND VENTILATION
REPAIRS 80-25
9.Remove 2 screws securing centre console
support bracket and remove bracket.
10.Remove 2 nuts securing RH fascia support
bracket and remove bracket. 11.Disconnect both evaporator drain hoses.
12.Remove front heater ducting.
13.Remove 4 nuts and bolt securing heater
assembly, release heater assembly from
bulkhead grommet and remove from vehicle.
Refit
1.Position heater assembly to bulkhead, locate
heater in bulkhead grommet.
2.Fit nuts and bolt securing heater and tighten to
16 Nm (12 lbf.ft).
3.Position RH fascia support bracket, fit and
tighten nuts.
4.Fit front heater ducting.
5.Position centre console support bracket, fit and
tighten screws.
6.Connect evaporator drain hoses.
7.Position heater motor to heater casing, fit nuts
and bolt and tighten to 19 Nm (14 lbf.ft).
8.Connect multiplug heater motor.
9.Position rear heater ducting and secure with
screws.
10.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia.
11.Using new 'O' rings, position air conditioning
pipes to evaporator fit bolts and tighten to 5 Nm
(3.7 lbf.ft).
12.Position heater hoses and secure hose clips.
13.Recharge air conditioning system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
14.Refill cooling system.
l
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
l
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
Page 1187 of 1529
HEATING AND VENTILATION
80-30REPAIRS
Pipe - Heater - Return
$% 80.25.12
Remove
1.Drain engine coolant.
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
2.Release clip securing heater return hose to
heater return pipe and disconnect hose from
pipe.
3.Remove bolt securing heater return pipe to
heater feed pipe.
4.Release clips securing engine harness and
vacuum pipe to heater return pipe.
5.Remove bolt securing heater return pipe to
cylinder head.
6.Release clip securing engine coolant hose to
heater return pipe.
7.Release engine coolant hose from heater
return pipe and collect pipe.Refit
1.Connect engine coolant hose to heater return
pipe and secure with clip.
2.Position heater return pipe to cylinder block and
secure with bolt.
3.Secure engine harness and vacuum pipe to
heater return pipe and secure with clips.
4.Fit and tighten bolt securing heater return pipe
to heater feed pipe.
5.Connect heater return hose to heater return
pipe and secure with clip.
6.Refill engine coolant.
+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
M80 0437
M80 0438
4
46
7
5
Page 1188 of 1529
HEATING AND VENTILATION
REPAIRS 80-31
Fuel burning heater - (FBH) - Td5
$% 80.40.01.99
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Clamp feed and return coolant hoses at FBH.
4.Position container to collect spillage.
5.Release clips, disconnect coolant feed and
return hoses from FBH.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
6.Disconnect 2 multiplugs from FBH.7.Position container to collect spillage and
disconnect quick release fuel pipe from FBH.
CAUTION: Before disconnecting any part of
the fuel system, it is imperative that all dust,
dirt and debris is removed from around
components to prevent ingress of foreign
matter into fuel system.
8.Remove Torx bolt securing FBH to bulkhead
mounting bracket.
9.Release and remove FBH.
10.Collect locating bushes from pegs.
Refit
1.Fit bushes to pegs.
2.Align FBH to pegs, fit Torx bolt and tighten to 25
Nm (18 lbf.ft).
3.Clean quick release connection and fit fuel pipe
to FBH.
4.Connect multiplugs to FBH.
5.Connect coolant hoses to FBH and secure with
clips.
6.Release clamps from hoses.
7.Connect battery earth lead.
8.Fit and secure battery cover.
9.Top-up cooling system.
+ MAINTENANCE, PROCEDURES,
Cooling system.