cooling system - td5 LAND ROVER DISCOVERY 2002 Repair Manual
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 596 of 1672
COOLING SYSTEM - TD5
ADJUSTMENTS 26-1-13
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.
5.Remove drain plug access cover from
underbelly panel.
6.Remove drain plug from coolant pump feed
pipe and allow cooling system to drain. Discard
drain plug sealing washer.
Refill
1.Flush system with water under low pressure.
Do not use water under high pressure as it
could damage the radiator.
2.Fit new sealing washer to drain plug. Fit and
tighten drain plug in coolant pump feed pipe.
3.Fit access cover to underbelly panel.
4.Prepare coolant to required concentration.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.5.Remove bleed screw from top hose.
6.Unclip the bleed hose from the battery box.
7.Unclip the expansion tank from its mounting
bracket, remove the expansion tank cap and
raise the expansion tank vertically 10 cm (4 in).
Retain the tank in this position.
8.Slowly fill the system through the coolant
expansion tank until a steady flow of coolant is
emitted from the bleed hole.
9.Fit the bleed screw, then, with the expansion
tank still raised, continue filling the system until
coolant level reaches the cold level mark on
expansion tank.
10.Fit expansion tank filler cap, fit the expansion
tank to its mounting bracket and clip the bleed
hose to the battery box.
11.Start and run engine until normal operating
temperature is reached, and check for leaks.
12.Switch off engine and allow to cool.
13.Check for leaks and top-up coolant to the cold
level mark on expansion tank
Page 597 of 1672
COOLING SYSTEM - TD5
26-1-14 ADJUSTMENTS
Page 598 of 1672
COOLING SYSTEM - TD5
REPAIRS 26-1-15
REPAIRS
Fan - viscous
$% 26.25.19
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove 3 bolts and remove engine acoustic
cover.
4.Remove upper fan cowl.
5.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. Fit engine acoustic cover and tighten bolts.
4.Connect battery earth lead.
5.Fit battery cover and secure with fixings.
Radiator
$% 26.40.01
Remove
1.Drain cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove intercooler.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
3.Remove clip and disconnect bleed hose from
radiator.
4.Release clip and disconnect top hose from
radiator.
5.Release clip and disconnect bottom hose from
radiator.
6.Release clip and disconnect engine oil cooler
hose from radiator.
7.Release clip and disconnect fuel cooler hose
from radiator.
Page 599 of 1672
COOLING SYSTEM - TD5
26-1-16 REPAIRS
8.Remove securing screw and release gearbox
oil cooler from radiator.
9.Remove radiator.
10.Remove rubber mountings from base of
radiator.
11.Remove 2 captive nuts from radiator.
12.Remove sealing strip from radiator.
13.Remove cowl retaining clips from radiator. Refit
1.Fit cowl retaining clips to radiator.
2.Fit sealing strip to radiator.
3.Fit nuts and rubber mountings to new radiator.
4.Fit radiator.
5.Fit gearbox oil cooler to radiator and secure
with screw.
6.Connect fuel and engine oil cooler hoses to
radiator and secure with clips.
7.Connect bottom and top hoses to radiator
secure with clips.
8.Connect bleed hose to radiator and fit clip.
9.Fit intercooler.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Intercooler.
10.Refill cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
Page 600 of 1672
COOLING SYSTEM - TD5
REPAIRS 26-1-17
Thermostat
$% 26.45.09
Remove
1.Drain cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove viscous fan.
+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
3.Loosen clips and release air intake hose from
EGR valve.
4.Remove air intake hose.
5.Release 3 clips and disconnect coolant hoses
from thermostat.
6.Remove thermostat. Refit
1.Position thermostat, connect hoses and secure
with clips.
2.Position air intake hose to EGR valve, connect
hose to intercooler and tighten clips.
3.Fit viscous fan.
+ COOLING SYSTEM - Td5, REPAIRS,
Fan - viscous.
4.Refill cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
Page 601 of 1672
COOLING SYSTEM - TD5
26-1-18 REPAIRS
Pump - coolant
$% 26.50.01
Remove
1.Drain cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
2.Remove centrifuge.
+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
3.Release clip and disconnect hose from coolant
pump cover.
4.Remove 5 bolts securing coolant pump cover.
5.Remove cover and coolant pump from housing
and discard 'O' rings. Refit
1.Clean coolant pump housing and mating faces.
2.Fit new 'O' rings to coolant pump and cover.
3.Fit coolant pump and cover and tighten bolts
to 9 Nm (7 lbf.ft).
4.Connect hose to pump cover and secure with
clip.
5.Refit centrifuge.
+ ENGINE - Td5, REPAIRS, Gasket -
centrifuge oil drain pipe.
6.Refill cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
Page 699 of 1672
MANUAL GEARBOX - R380
37-16 REPAIRS
Gearbox - Diesel
$% 37.20.02.99
Remove
1.Release turn buckles and remove battery cover
and cooling fan cowl.
2.Disconnect battery earth lead.
3.Remove gear lever knob and gear lever trim.
4.Remove clamp bolt and remove gear lever
extension.
5.Apply a little lubricant to gear lever to aid
removal through grommet.
6.Remove exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.7.Remove starter motor.
+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
8.Drain gearbox oil.
+ MAINTENANCE, PROCEDURES,
Manual gearbox.
9.Drain transfer gearbox oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
10.Remove 3 nuts securing intermediate silencer
to tail pipe.
11.Release silencer from mounting rubbers,
remove silencer and discard gasket.
12.Remove front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front.
13.Remove rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
Page 702 of 1672
MANUAL GEARBOX - R380
REPAIRS 37-19
32.Remove 8 bolts securing gearbox to engine.
33.With assistance, remove gearbox from engine.
Refit
1.Clean gearbox to engine mating faces, dowels
and dowel holes.
2.With assistance raise gearbox on jack and
align to clutch and engine.
3.Fit bolts securing gearbox to engine and
tighten to 50 Nm (37 lbf.ft).
4.Clean oil cooling pipe housing mating faces.
5.Lubricate and fit new 'O' rings to oil cooling
pipe housing.
6.Position cooling pipe housing, fit bolts and
tighten to 25 Nm (18 lbf.ft).
7. If fitted: Secure harness in retaining clips,
connect Lucars to differential lock warning
switch and multiplug to transfer box neutral
switch.
8.Position breather pipes and secure 'P' clip with
bolt.
9.Using new sealing washers fit breather pipe
banjo bolts and tighten to 15 Nm (11 lbf.ft).
10.Connect oil temperature sensor Lucars and
reverse lamp switch multiplug.
11.Position low ratio selector cable to housing and
secure with 'C' washer and clevis pin.
12.Secure cable to fuel pipes with new cable ties. 13.Raise gearbox, ensuring gear change lever is
located in grommet.
14.Fit gearbox mountings and tighten bolts to 85
Nm (63 lbf.ft).
15.Fit nuts to gearbox mountings and tighten to 48
Nm (37 lbf.ft).
16.Remove 3 bolts securing support plate to
gearbox.
17.Position clutch slave cylinder and heat shield,
fit bolts and tighten to 25 Nm (18 lbf.ft).
18.Clean handbrake back plate and mating face.
19.Position handbrake back plate, fit bolts and
tighten to 75 Nm (55 lbf.ft).
20.Clean handbrake drum.
21.Fit handbrake drum and tighten retaining
screw.
22.Fit front propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - front..
23.Fit rear propeller shaft.
+ PROPELLER SHAFTS, REPAIRS,
Propeller shaft - rear.
24.Clean exhaust silencer and tail pipe mating
faces.
25.Position silencer and secure on mountings,
using a new gasket align to tail pipe, fit nuts
and tighten to 25 Nm (18 lbf.ft).
26.Fit exhaust front pipe.
+ MANIFOLDS AND EXHAUST
SYSTEMS - Td5, REPAIRS, Pipe - front.
27.Refit starter motor.
+ CHARGING AND STARTING,
REPAIRS, Starter motor - diesel.
28.Refill gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Manual gearbox.
29.Refill transfer gearbox with oil.
+ MAINTENANCE, PROCEDURES,
Transfer box.
30.Fit gear lever extension, fit clamp bolt and
tighten to 25 Nm (18 lbf.ft).
31.Fit gear lever trim and gear change knob.
32.Connect battery earth lead.
33.Fit cooling fan cowl and battery cover and
secure fixings.
Page 917 of 1672
STEERING
57-30 REPAIRS
Power steering box - LHD - diesel
$% 57.10.01
Remove
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Drain cooling system.
+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
4.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.
5.Remove LH front road wheel.
6.Ensure steering wheel is centralised, remove
key from steering lock and engage column lock.
7.Fit centralising bolt to steering box.
8.Loosen 2 clips securing intercooler to turbo
hose. Remove hose.9.Remove 3 bolts securing intermediate shaft
and universal joint.
10.Push intermediate shaft upwards, release and
remove universal joint.
CAUTION: Do not turn the steering wheel
with the intermediate shaft or universal joint
disconnected as damage to the rotary
coupler and the steering wheel switches
may occur.
11.Position container below PAS pipes to catch
fluid spillage.
Page 920 of 1672
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.