coolant LAND ROVER DISCOVERY 2002 Workshop Manual

STEERING
REPAIRS 57-33
21.With assistance remove 2 nuts and bolts
securing RH engine mounting to chassis.
22.Support the engine weight on a jack.
CAUTION: To prevent damage to
components, cushion the jack pad with a
block of wood or hard rubber.
23.Raise the engine sufficiently to allow the
steering box to clear the sump.
24. Models with ACE: Position ACE control arms
to access steering box bolts. 25.With assistance remove 4 bolts securing
steering box and remove steering box.
26.Remove centralising bolt from steering box.
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3.Lower the engine onto its mountings. Fit engine
mounting bolts and tighten to 85 Nm (63 lbf.ft).
4. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle. Tighten nut to
100 Nm (74 lbf.ft).
5.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
6.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
7.Position coolant rail and secure with clips and
bolt.
8.Fit coolant hoses and secure with clips.
9. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
10.Clean PAS pipe ends and 'O' ring recess.
11.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
12.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
13.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
14.Remove centralising bolt from steering box.
15.Fit intercooler to turbo hose and secure with
clips.
16.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
17.Remove stand(s) and lower vehicle.
18.Connect battery earth lead.
19.Fit battery cover.
20.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
21.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
22.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

STEERING
REPAIRS 57-35
11.Remove bolt securing PAS pipe bracket to
steering box, release pipes and discard 'O'
rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Release 5 clips securing hoses to coolant rail
release and disconnect hoses.
13. Models with ACE: Remove bolt securing ACE
pipes to chassis to gain access to coolant rail
bolt.
14.Remove bolt securing coolant rail. 15.Release 2 clips securing coolant rails and
remove coolant rail from vehicle.
16.Remove securing nut and bolt and release
Panhard rod.

STEERING
57-36 REPAIRS
17.Remove nut securing drag link to drop arm.
Using LRT-57-036, break taper joint and
release drag link.
18. Models with ACE: Remove nut securing anti-
roll bar link lower ball joint and release joint. 19. Models with ACE: Position ACE control arms
to access steering box bolts.
20.With assistance, remove 4 bolts securing
steering box and remove steering box.
21.Remove centralising bolt from steering box.
Refit
1.Fit centralising bolt to steering box.
2.With assistance, position steering box to
chassis, fit bolts and tighten to 90 Nm (66 lbf.ft).
3. Models with ACE: Ensure washer is in place
on lower ball joint of anti-roll bar link, then
connect lower ball joint to axle and tighten nut
to 100 Nm (74 lbf.ft).
4.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
5.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
6.Position coolant rail and secure with clips and
bolt.
7.Fit coolant hoses and secure with clips.
8. Models with ACE: Fit and tighten bolt
securing ACE pipes to chassis.
9.Clean PAS pipes ends and 'O' ring recess.

STEERING
57-42 REPAIRS
Refit
1.Clean PAS pump and adaptor pipe.
2.Fit new 'O' ring to adaptor pipe, fit pipe and
tighten bolts to 10 Nm (7 lbf.ft).
3.Position mounting bracket to PAS pump, fit but
do not tighten bolt.
4.Position PAS pump and align pump drive to
coolant pump. Fit and tighten bolts to 25 Nm
(18 lbf.ft).
5.Tighten mounting plate bolt to 25 Nm (18 lbf.ft).
6.Clean PAS pump and pipe union.
7.Fit and tighten PAS pump pressure pipe to 20
Nm (15 lbf.ft).
8.Fit PAS pump inlet hose and secure with clip.
9.Clean PAS pump and pulley mating faces.
10.Position PAS pump pulley, fit and tighten bolts
to 10 Nm (7 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
12.Bleed power steering system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
Steering column assembly and lock
$% 57.40.01
Remove
1.Remove steering column intermediate shaft.

+ STEERING, REPAIRS, Shaft -
intermediate and universal joint - steering
column.
2.Remove rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
3.Open fascia lower access panel.
4.Remove steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
5.Disconnect multiplug and illumination bulb
from passive coil and remove passive coil.

FRONT SUSPENSION
REPAIRS 60-37
6.Apply a 3 mm (0.125 in) wide bead of Loctite
640 around drive shaft circumference, as
illustrated.
7.Ensure ABS harness is located in cut out in
steering knuckle.
8.Fit wheel hub to drive shaft and align steering
knuckle. The Loctite will smear along the length
of the splines as the wheel hub is fitted to the
drive shaft.
9.Fit wheel hub bolts and tighten to 100 Nm (74
lbf.ft).
10.Fit new drive shaft nut and lightly tighten.
11.Fit front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
12.With assistance, final tighten drive shaft nut to
490 Nm (360 lbf.ft). Stake drive shaft nut. The
drive shaft nut must be tightened before
Loctite has cured.
13.Secure ABS sensor harness to brackets and
secure grommet to inner wing.
14.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect ABS sensor multiplug.
Damper - front
$% 60.30.02
Remove
1.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.
2.Remove road wheel.
3. RH damper: Release coolant reservoir and
position aside.
4.Loosen through bolt securing damper to turret.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
M51 0058

FRONT SUSPENSION
60-38 REPAIRS
5.Remove 4 nuts securing turret base to chassis.
6.Remove 2 bolts securing damper to axle.
7. ACE models: Remove bolt securing ACE pipe
clamp to chassis.
8. ACE models: Remove bolt securing ACE pipe
clamp to turret.
9.Release harness clip from turret.
10.Raise turret and remove through bolt.
11.Compress damper and manoeuvre turret from
engine bay.
12.Remove damper. Refit
1.Position damper and manoeuvre turret into
position. Raise damper and align to turret. Fit
through bolt but do not tighten at this stage.
2.Align damper assembly to spring seat.
3.Fit bolts securing damper to axle and tighten to
45 Nm (33 lbf.ft).
4.Fit nuts securing turret to chassis and tighten
to 23 Nm (17 lbf.ft).
5.Tighten through bolt to 125 Nm (92 lbf.ft).
6. ACE models: Position ACE pipe clamp to
chassis and secure with bolt.
7. ACE models: Position ACE pipe clamp to
turret and secure with bolt.
8.Secure harness to turret.
9. RH damper: Reposition coolant reservoir.
10.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
11.Remove stand(s) and lower vehicle.

FRONT SUSPENSION
REPAIRS 60-59
15.Release clips and disconnect 2 thermostat
housing hoses from coolant pipe.
16.Release clip and disconnect bottom hose from
radiator.
17.Remove thermostat housing with hoses.
18.Position container to collect ACE fluid loss.
19. Pump to valve block pipe: Remove banjo
bolt securing fluid hose to ACE pump and
discard sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.20. Valve block to reservoir pipe: Release clip,
disconnect hose from ACE fluid reservoir and
remove clip from hose.
CAUTION: Always fit plugs to open
connections to prevent contamination.
21.Remove bolts securing 2 pipe clamps to
chassis front cross member and remove
clamps.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-3
Description
General
The heating and ventilation system controls the temperature and distribution of air supplied to the vehicle interior. The
system consists of an air inlet duct, heater assembly, distribution ducts and a control panel. An outlet vent is
incorporated at the rear of the cabin. Some diesel models also incorporate a fuel burning heater (FBH) system in the
engine coolant supply to the heater assembly.
Fresh or recirculated air flows into the heater assembly from the inlet duct. An electrical variable speed blower in the
inlet duct, and/or ram effect, forces the air through the system. Depending on the settings on the control panel, the air
is then heated and supplied through the distribution ducts to fascia and floor level outlets.

HEATING AND VENTILATION
DESCRIPTION AND OPERATION 80-5
Heater assembly
1Windscreen and side window air outlet
2Face level air outlet
3Casing
4Rear footwell air outlet
5Front footwell air outlet
6Drain outlet
7Air inlet8Engine coolant return
9Engine coolant feed
10Heater matrix
11RH temperature control cable
12Distribution control cable
13LH temperature control cable
The heater assembly heats and distributes air as directed by selections made on the control panel. The assembly is
installed on the vehicle centre-line, between the fascia and the engine bulkhead. The heater assembly consists of a
casing, formed from a series of plastic moldings, which contains a heater matrix and control flaps. Internal passages
integrated into the casing guide the air through the casing and separate it into two flows, one for the LH outlets and
one for the RH outlets. Two drain outlets at the bottom of the casing connect to overboard drain tubes installed in the
sides of the transmission tunnel.
Heater matrix
The heater matrix provides the heat source to warm the air being supplied to the distribution outlets. The heater matrix
is an aluminium two pass, fin and tube heat exchanger, installed in the RH side of the casing. Two aluminium tubes
attached to the heater matrix extend through the engine bulkhead to connect the heater assembly to the engine
coolant system. When the engine is running, coolant is constantly circulated through the heater matrix by the engine
coolant pump. On diesel models, the coolant flow is assisted by an electric pump while the FBH system is active.

HEATING AND VENTILATION
80-8DESCRIPTION AND OPERATION
Control panel
The controls for heating and ventilation are installed on a control panel in the centre of the fascia, below the radio.
Three rotary knobs control the LH and RH outlet temperatures and distribution. A slider switch controls blower speed.
A latching pushswitch controls the selection of fresh/recirculated air; an amber LED in the switch illuminates when
recirculated air is selected.
Graphics on the panel and the controls indicate the function and operating positions of the controls.
Outlet vent
The outlet vent promotes the free flow of heating and ventilation air through the cabin. The outlet vent is installed in
the RH rear quarter body panel and vents cabin air into the sheltered area between the rear quarter body panel and
the outer body side panel. The vent consists of a grille covered by soft rubber flaps and is effectively a non-return
valve. The flap opens and closes automatically depending on the differential between cabin and outside air pressures.
FBH system (diesel models only)
The FBH system is an auxiliary heating system that compensates for the relatively low coolant temperatures inherent
in the diesel engine. At low ambient temperatures, the FBH system heats the coolant supply to the heater assembly,
and maintains it within the temperature range required for good in-car heating performance. Operation is fully
automatic, with no intervention required by the driver.
The system consists of an air temperature sensor, a FBH fuel pump and a FBH unit. Fuel for the FBH system is taken
from the fuel tank, through a line attached to the fuel tank's fuel pump, and supplied via the FBH fuel pump to the FBH
unit. The connection on the fuel tank's fuel pump incorporates a tube which extends down into the tank. At the FBH
unit connection, the fuel line incorporates a self-sealing, quick disconnect coupling. In the FBH unit, the fuel delivered
by the FBH fuel pump is burned and the resultant heat output is used to heat the coolant. An ECU integrated into the
FBH unit controls the operation of the system at one of two heat output levels, 2.5 kW at part load and 5 kW at full load
Ambient temperature sensor
The ambient temperature sensor controls a power supply from the alternator to the FBH unit. The sensor is installed
on the RH support strut of the bonnet closing panel and contains a temperature sensitive switch that is closed at
temperatures below 5
°C (41 °F) and open at temperatures of 5 °C (41 °F) and above.