radiator LAND ROVER DISCOVERY 2002 Service Manual

COOLING SYSTEM - V8
26-2-12 DESCRIPTION AND OPERATION
As the coolant temperature increases, the heat emitted from the radiator causes the bi-metallic coil to tighten. This
movement of the coil moves the valve to which it is attached. The rotation of the valve exposes ports in the valve plate
which allow silicone fluid to spill into the fluid chamber. As the fluid flows into the clearance between the annular
grooves in the drive plate and body, drag is created between the two components. The drag is due to the viscosity
and shear qualities of the silicone fluid and cause the drive plate to rotate the body and fan blades.
As the coolant temperature decreases, the bi-metallic coil expands, rotating the valve and closing off the ports in the
valve plate. When the valve is closed, centrifugal force pushes silicone fluid through the return port, emptying the fluid
chamber. As the fluid chamber empties, the drag between the drive plate and the body is reduced and the body slips
on the drive plate, slowing the rotational speed of the fan.

COOLING SYSTEM - V8
ADJUSTMENTS 26-2-13
ADJUST ME NTS
Drain and refill
$% 26.10.01
WARNING: Since injury such as scalding could
be caused by escaping steam or coolant, do not
remove the filler cap from the coolant expansion
tank while the system is hot.
Drain
1.Visually check engine and cooling system for
signs of coolant leaks.
2.Examine hoses for signs of cracking, distortion
and security of connections.
3.Position drain tray to collect coolant.
4.Remove expansion tank filler cap.
LH side
RH side5.Remove drain plugs from LH and RH sides of
cylinder block and allow cooling system to
drain.
6.Disconnect bottom hose from radiator and
allow cooling system to drain.
7.Disconnect top hose from thermostat and
position open end of hose below level of
coolant pump inlet, to allow coolant to drain
from the system.
Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Apply Loctite 577 to cylinder block drain
plugs.Fit drain plugs to cylinder block and
tighten to 30 Nm (22 lbf.ft).
3.Connect bottom hose to radiator and top hose
to thermostat housing. Secure with hose clips.
4.Prepare coolant to required concentration.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.

COOLING SYSTEM - V8
REPAIRS 26-2-15
REPAIRS
Fan - viscous
$% 26.25.19
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove upper fan cowl.
4.Remove viscous fan using tool LRT-12-093
and tool LRT-12-094.
RH thread.
Refit
1.Position viscous fan and tighten using tool
LRT-12-093 and tool LRT-12-094.
2.Fit upper fan cowl.
3.Connect battery earth lead.
4.Fit battery cover and secure fixings.
Radiator
$% 26.40.01
Remove
1.Remove viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
2.Drain cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.
3.Remove 2 screws and remove lower of fan
cowl.
4.Release clip and disconnect bottom hose from
thermostat housing.
5.Release clip and disconnect top hose from
radiator.
6.Remove clip and disconnect bleed hose from
radiator.
7.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.

COOLING SYSTEM - V8
26-2-16 REPAIRS
8.Remove 6 scrivets and remove LH and RH air
deflectors from front panel. Disconnect
multiplug of gearbox oil temperature sensor
(arrowed).
9.Remove nut and move horn aside. 10.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
11.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
12.Remove brackets with rubber mounts from
radiator extension brackets.
13.Position absorbent cloth under each cooler
hose to collect oil spillage.
14.Push against coupling release rings and
disconnect hoses from gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
15. If fitted: Push against coupling release rings
and disconnect hoses from engine oil cooler.

COOLING SYSTEM - V8
REPAIRS 26-2-17
16.Remove radiator assembly.
17.Release clip and remove bottom hose from
radiator.
18.Remove 2 bolts and remove extension
brackets from radiator.
19.Remove 2 captive nuts from radiator.
20.Remove 2 screws and remove gearbox oil
cooler from radiator.
21. If fitted: Remove 2 screws and remove engine
oil cooler from radiator.
22.Remove 2 rubber mountings from radiator.
23.Remove sealing strip from bottom of radiator.
24.Remove 2 cowl retaining clips from radiator. Refit
1.Fit cowl retaining clips to radiator.
2.Fit sealing strip to radiator.
3.Fit rubber mountings to radiator.
4.Fit gearbox oil cooler to radiator and secure
with screws.
5. If fitted: Fit engine oil cooler to radiator and
secure with screws.
6.Fit captive nuts to radiator.
7.Fit extension brackets to radiator and secure
with bolts.
8.Fit bottom hose to radiator and secure with clip.
9.Fit radiator and engage lower mountings in
chassis.
10.Ensure connections are clean, then secure
hoses to oil coolers.
11.Fit air conditioning condenser brackets and
secure with screws.
12.Fit radiator upper mounting brackets and
secure with bolts.
13.Fit LH horn and secure with nut.
14.Fit air deflectors and secure with scrivets.
15.Connect multiplug of gearbox oil temperature
sensor.
16.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
17.Connect bottom hose to thermostat housing
and secure with clip.
18.Connect top hose to radiator and secure with
clip.
19.Connect bleed hose to radiator and fit clip.
20.Fit lower fan cowl and secure with screws.
21.Fit viscous fan.

+ COOLING SYSTEM - V8, REPAIRS,
Fan - viscous.
22.Top up gearbox oil.
23.Top up engine oil.
24.Refill cooling system.

+ COOLING SYSTEM - V8,
ADJUSTMENTS, Drain and refill.

MANIFOLDS AND EXHAUST SYSTEMS - V8
DESCRIPTION AND OPERATION 30-2-5
Description
General
The inlet manifold on the V8 engine is located on the top of the engine, between the cylinders. The manifold directs
intake air into the cylinders. The intake air is mixed with fuel delivered by the injectors prior to ignition in the cylinders.
The inlet manifold comprises three separate aluminium castings.
Two exhaust manifolds are used, one for each bank of four cylinders. Each exhaust manifold allows combustion
gases from the cylinders to leave the engine and directs them into the exhaust system.
The exhaust system is connected to each exhaust manifold and merges into one pipe midway along the underside of
the vehicle. A catalytic converter (where fitted) is located in the front pipe from each manifold. A silencer is installed
midway along the system and a second tail silencer is located at the rear of the vehicle.
Inlet manifold
The inlet manifold comprises three aluminium castings; a lower manifold, an upper manifold and a plenum. The inlet
manifold is located on the top of the engine and feeds air into the cylinders.
Lower manifold
The lower manifold is a one piece machined aluminium casting which locates in the vee on the top of the engine and
is secured to each cylinder head with six bolts per head. A one piece coated metal gasket seals the lower manifold to
each cylinder head and also serves as a cover for the cylinder block.
Eight injectors are fitted into the lower manifold, four on each side. Each injector is sealed in the manifold with O-ring
seals and retained in position by the fuel rails. A fuel rail is attached to each side of the manifold and secured with two
bolts.
Eight air intake ports are cast and machined on the top of the manifold, each port directing intake air into one cylinder.
These ports mate with matching ports in the upper manifold and are sealed with a coated metal gasket between the
two manifolds.
A cavity at the front of the manifold collects coolant flow from the engine. A coolant outlet pipe is sealed and attached
to the front of the manifold and provides for coolant to flow through the cavity in the casting to the radiator top hose.
A smaller port in the manifold also allows coolant to flow from the cavity to the heater matrix. The lower manifold also
locates the Engine Coolant Temperature (ECT) sensor in a port in the front of the manifold.
Upper manifold
The upper manifold is a one piece machined aluminium casting. The manifold has eight ports on its lower face which
mate with the eight ports on the lower manifold. The joint between the upper and lower manifolds is sealed with a
coated metal gasket and secured with six bolts.
The manifold divides from the eight ports into eight branches, four on each side. Each set of four branches merge into
one gallery on each side of the manifold. Each gallery has an opening at its forward end which mates with the intake
plenum.
The upper manifold provides attachment for the Idle Air Control (IAC) valve and for brackets which retain pipes, plug
leads and throttle cables.

MANUAL GEARBOX - R380
37-22 REPAIRS
Refit
1.Using a suitable solvent clean seal housing
mating faces.
2.Clean seal recess, bearings and bearing races.
3.Lubricate new oil seal and fit using a suitable
mandrel into housing.
4.Fit input shaft front bearing track using a press
and suitable mandrel.
5.Apply sealant, Part No. STC 4404 to seal
housing.
6.Position seal housing, fit new bolts and tighten
by diagonal selection to 25 Nm (18 lbf.ft).
7.Clean bell housing mating faces, dowels and
dowel holes.
8.Position bell housing, fit bolts and tighten to 75
Nm (55 lbf.ft).
9.Clean release bearing sleeve mating faces,
dowel and dowel holes.
10.Position release bearing sleeve, fit bolts and
tighten to 25 Nm (18 lbf.ft).
11.Examine clutch release fork pivot points for
wear and replace as required.
12.Apply a smear of Molybdenum disulphide
grease to pivot points and position release
fork.
13.Fit retaining clip ensuring it locates over pivot
point washer, fit release fork bolt and tighten to
10 Nm (7 lbf.ft).
14.Clean release bearing and bearing sleeve
mating faces.
15.Apply smear of Molybdenum disulphide grease
to release bearing sleeve.
16.Fit release bearing and secure with retaining
peg.
17.Fit gearbox assembly.

+ MANUAL GEARBOX - R380,
REPAIRS, Gearbox - V8.
Cooler - oil - gearbox - Diesel
$% 37.24.02
Remove
1.Remove intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release ring and
disconnect both fluid hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.

MANUAL GEARBOX - R380
REPAIRS 37-23
5.Release oil cooler from location on radiator,
and remove the oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Fit oil cooler to radiator and secure with screw.
2.Ensure connections are clean and secure
hoses to cooler.
3.Fit intercooler.

+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
4.Top up gearbox oil level.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
Cooler - oil - gearbox - V8
$% 37.24.02
Remove
1. If fitted: Remove engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
2.Position absorbent cloth under each gearbox
oil cooler hose connection to collect spillage.
3.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Remove screw securing oil cooler to radiator.
5.Release oil cooler from its location on radiator.

MANUAL GEARBOX - R380
37-24 REPAIRS
6.Move radiator towards engine sufficiently only
to release gearbox oil cooler from radiator.
7.Remove gearbox oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
Refit
1.Fit gearbox oil cooler to radiator, engage in
location and secure with screw.
2.Ensure connections are clean and secure
hoses to cooler.
3. If fitted: Fit engine oil cooler.

+ ENGINE - V8, REPAIRS, Cooler -
engine oil.
4.Top up gearbox oil.

+ MAINTENANCE, PROCEDURES,
Manual gearbox.
Switch - Reverse light
$% 37.27.01
Remove
1.Raise vehicle on ramp.
2.Disconnect reverse lamp switch multiplug.
3.Remove switch and collect sealing washer.
Refit
1.Clean switch and mating face on gearbox.
2.Using a new sealing washer, fit the reverse light
switch and tighten to 24 Nm (17 lbf.ft).
3.Connect switch multiplug.
4.Lower vehicle.

AUTOMATIC GEARBOX - ZF4HP22 - 24
DESCRIPTION AND OPERATION 44-13
Oil cooler
1Inlet connection
2Fixing bracket
3Outlet connection
4Fixing bracket
5Temperature sensor
Transmission fluid from the gearbox is circulated through a cooler attached to the front of the radiator. Quick release
connectors on the transmission fluid lines attach to connections on each end tank of the cooler. A temperature sensor
on the RH end tank provides the instrument pack with an input of transmission fluid temperature. If the temperature
exceeds a preset limit, the instrument pack illuminates the transmission temperature warning lamp. The warning lamp
remains illuminated until the temperature of the fluid returns within limits.
EAT ECU
The EAT ECU operates the solenoid valves in the gearbox to provide automatic control of gear shifts and torque
converter lock-up. The EAT ECU is attached to a protective bracket which is secured to the cabin floor below the LH
front seat. A 55 pin connector links the EAT ECU to the vehicle wiring.
Software in the EAT ECU monitors hard wired inputs and exchanges information with the ECM on a Controller Area
Network (CAN) bus to determine gear shift and torque converter lock-up requirements. Resultant control signals are
then output to the gearbox solenoid valves.