LAND ROVER DISCOVERY 2002 Workshop Manual

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.

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-1
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COOLING SYSTEM - V8 DESCRIPTION AND OPERAT ION

COOLING SYSTEM - V8
26-2-2 DESCRIPTION AND OPERATION
Cooling system component layout

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-3
1Heater matrix
2Heater return hose
3Heater inlet hose
4Heater inlet pipe
5Throttle housing
6Connecting hose
7Throttle housing inlet hose
8Throttle housing return pipe
9Manifold outlet pipe
10Heater return pipe
11Coolant pump
12Radiator top hose
13Connecting hose
14Radiator bleed pipe15Viscous fan
16Radiator
17Gearbox oil cooler
18Engine oil cooler (Only applicable to vehicles
up to VIN 756821)
19Radiator bottom hose
20Thermostat housing
21Bleed screw
22Coolant pump feed hose
23Expansion tank
24Pressure cap
25Connecting hose
26Overflow pipe

COOLING SYSTEM - V8
26-2-4 DESCRIPTION AND OPERATION
Cooling system coolant flow

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-5
1Heater matrix
2Heater return hose
3Heater inlet hose
4Heater inlet pipe
5Throttle housing
6Throttle housing inlet hose
7Throttle housing return pipe
8Manifold outlet pipe
9Heater return pipe
10Coolant pump11Bleed screw
12Radiator top hose
13Radiator bleed pipe
14Radiator
15Radiator bottom hose
16Thermostat housing
17Coolant pump feed hose
18Expansion tank
19Pressure cap
20Overflow/breather pipe

COOLING SYSTEM - V8
26-2-6 DESCRIPTION AND OPERATION
Description
General
The cooling system used on the V8 engine is a pressure relief by-pass type system which allows coolant to circulate
around the cylinder block and the heater circuit when the thermostat is closed. With coolant not passing through the
radiator, this promotes faster heater warm-up which in turn improves passenger comfort.
A coolant pump is located in a housing at the front of the engine and is driven by a drive belt. The pump is connected
into the coolant passages cast in the cylinder block and pumps coolant from the radiator through the cylinder block.
A viscous fan is attached by means of a nut to the coolant pump pulley drive spindle. The fan draws air through the
radiator to assist in cooling when the vehicle is stationary. The fan rotational speed is controlled relative to the running
temperature of the engine by a thermostatic valve regulated by a bi-metallic coil.
The cooling system uses a 50/50 mix of anti-freeze and water.
Thermostat housing
A plastic thermostat housing is located behind the radiator. The housing has three connections which locate the
radiator bottom hose, top hose and coolant pump feed hose. The housing contains a wax element and a spring loaded
by-pass flow valve.
Thermostat - Main valve
The thermostat is used to maintain the coolant at the optimum temperature for efficient combustion and to aid engine
warm-up. The thermostat is closed at temperatures below approximately 82
°C (179°F). When the coolant
temperature reaches approximately 82
°C the thermostat starts to open and is fully open at approximately 96°C
(204
°F). In this condition the full flow of coolant is directed through the radiator.
The thermostat is exposed to 90% hot coolant from the engine on one side and 10% cold coolant returning from the
radiator bottom hose on the other side.
Hot coolant from the engine passes from the by-pass pipe through four sensing holes in the flow valve into a tube
surrounding 90% of the thermostat sensitive area. Cold coolant returning from the engine, cooled by the radiator,
conducts through 10% of the sensitive area.
In cold ambient temperatures, the engine temperature is raised by approximately 10
°C (50°F) to compensate for the
heat loss of 10% exposure to the cold coolant returning from the bottom hose.
By-pass flow valve
The by-pass flow valve is held closed by a light spring. It operates to further aid heater warm-up. When the main valve
is closed and the engine speed is at idle, the coolant pump does not produce sufficient flow and pressure to open the
valve. In this condition the valve prevents coolant circulating through the by-pass circuit and forces the coolant through
the heater matrix only. This provides a higher flow of coolant through the heater matrix to improve passenger comfort
in cold conditions.
When the engine speed increases above idle the coolant pump produces a greater flow and pressure than the heater
circuit can take. The pressure acts on the flow valve and overcomes the valve spring pressure, opening the valve and
limiting the pressure in the heater circuit. The valve modulates to provide maximum coolant flow through the heater
matrix and yet allowing excess coolant to flow into the by-pass circuit to provide the engine's cooling needs at higher
engine rev/min.

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-7
Inlet manifold - Cooling connections
Coolant leaves the cylinder block via an outlet pipe attached to the front of the air intake manifold. The pipe is
connected to the thermostat housing and the radiator by a branch hose off the radiator top hose.
Hot coolant from the engine is also directed from the inlet manifold via pipes and hoses into the heater matrix. Coolant
is circulated through the heater matrix at all times when the engine is running.
A further tapping from the inlet manifold supplies coolant to the throttle housing via a hose. The coolant circulates
through a plate attached to the bottom of the housing and is returned through a plastic bleed pipe to an expansion
tank. The hot coolant heats the air intake of the throttle housing preventing ice from forming.
An Engine Coolant Temperature (ECT) sensor is fitted in the inlet manifold adjacent to the manifold outlet pipe. The
sensor monitors coolant temperature emerging from the engine and sends signals to the ECM for engine
management and temperature gauge operation.

+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - engine
management.
Expansion tank
The expansion tank is located in the engine compartment. The tank is made from moulded plastic and attached to
brackets on the right hand inner wing. A maximum coolant when cold level is moulded onto the tank.
Excess coolant created by heat expansion is returned to the expansion tank from the radiator bleed pipe at the top of
the radiator. An outlet pipe is connected into the pump feed hose and replaces the coolant displaced by heat
expansion into the system when the engine is cool.
The expansion tank is fitted with a sealed pressure cap. The cap contains a pressure relief valve which opens to allow
excessive pressure and coolant to vent through the overflow pipe. The relief valve opens at a pressure of 1.4 bar (20
lbf.in
2) and above.
Heater matrix
The heater matrix is fitted in the heater assembly inside the passenger compartment. Two pipes pass through the
bulkhead into the engine compartment and provide coolant flow to and from the matrix. The pipes from the bulkhead
are connected to the matrix, sealed with 'O' rings and clamped with circular rings.
The matrix is constructed from aluminium with two end tanks interconnected with tubes. Aluminium fins are located
between the tubes and conduct heat away from the hot coolant flowing through the tubes. Air from the heater
assembly is warmed as it passes through the matrix fins. The warm air is then distributed into the passenger
compartment as required.

+ HEATING AND VENTILATION, DESCRIPTION AND OPERATION, Description.When the engine is
running, coolant from the engine is constantly circulated through the heater matrix.
Radiator
The 45 row radiator is located at the front of the vehicle. The cross-flow type radiator is manufactured from aluminium
with moulded plastic end tanks interconnected with tubes. Aluminium fins are located between the tubes and conduct
heat from the hot coolant flowing through the tubes, reducing the cooling temperature as it flows through the radiator.
Air intake from the front of the vehicle when moving carries heat away from the fins. When the vehicle is stationary,
the viscous fan draws air through the radiator fins to prevent the engine from overheating.
Two connections at the top of the radiator provide for the attachment of the top hose and bleed pipe. A connection at
the bottom of the radiator allows for the attachment of the bottom hose to the thermostat housing.
Two smaller radiators are located in front of the cooling radiator. The lower radiator provides cooling of the gearbox
oil and the upper radiator provides cooling for the engine oil.

+ MANUAL GEARBOX - R380, DESCRIPTION AND OPERATION, Description.

+ AUTOMATIC GEARBOX - ZF4HP22 - 24, DESCRIPTION AND OPERATION, Description.

+ ENGINE - V8, DESCRIPTION AND OPERATION, Description.

COOLING SYSTEM - V8
26-2-8 DESCRIPTION AND OPERATION
Pipes and hoses
The coolant circuit comprises flexible hoses and metal formed pipes which direct coolant into and out of the engine,
radiator and heater matrix. Plastic pipes are used for the bleed and overflow pipes to the expansion tank.
A bleed screw is installed in the radiator top hose and is used to bleed air during system filling. A drain plug is fitted
to each cylinder bank in the cylinder block. These are used to drain the block of coolant.
Coolant pump
1Pulley flange
2Body
3Impeller
4Gallery
5Inlet connection
The coolant pump is attached to the front of the cylinder block with nine bolts and sealed between the pump housing
and the cylinder block with a gasket. The pump comprises a shaft which passes through an alloy housing. The outer
end of the shaft has a flange which allows for the attachment of the pump drive pulley which is secured with three
bolts. The drive pulley is driven by the grooved auxiliary drive belt and rotates at the same speed as the crankshaft.
The inner end of the shaft is fitted with an impeller which draws coolant from the thermostat housing and circulates it
through the galleries in the cylinder block and through the heater matrix.
The shaft is supported on bearings in the housing which are packed with grease and sealed for life. A seal is
positioned in the housing to further protect the bearings from the ingress of coolant. The seal is manufactured from a
synthetic material which will allow for expansion of the casing when hot coolant is present.
The cast alloy housing has a hose connection which provides the attachment for the coolant pump feed hose. The
cast housing connects with galleries in the cylinder block and distributes coolant from the pump impeller into the
galleries and water jackets.

COOLING SYSTEM - V8
DESCRIPTION AND OPERATION 26-2-9
Viscous fan
1Coolant pump pulley drive attachment
2Fan blades
3Bi-metallic coil
4Body
The viscous fan provides a means of controlling the speed of the fan relative to the operating temperature of the
engine. The fan rotation draws air through the radiator, reducing engine coolant temperatures when the vehicle is
stationary or moving slowly.
The viscous fan is attached to the coolant pump drive pulley and secured to the pulley by a nut. The nut is positively
attached to a spindle which is supported on bearings in the fan body. The viscous drive comprises a circular drive
plate attached to the spindle and driven from the coolant pump pulley and the coupling body. The drive plate and the
body have interlocking annular grooves with a small clearance which provides the drive when silicone fluid enters the
fluid chamber. A bi-metallic coil is fitted externally on the forward face of the body. The coil is connected to and
operates a valve in the body. The valve operates on a valve plate with ports that connect the reservoir to the fluid
chamber. The valve plate also has return ports which, when the valve is closed, scoop fluid from the fluid chamber
and push it into the reservoir under centrifugal force.
Silicone fluid is retained in a reservoir at the front of the body. When the engine is off and the fan is stationary, the
silicone fluid level stabilises between the reservoir and the fluid chamber. This will result in the fan operating when the
engine is started, but the drive will be removed quickly after the fan starts rotating and the fan will 'freewheel'.
At low radiator temperatures, the fan operation is not required and the bi-metallic coil keeps the valve closed,
separating the silicone fluid from the drive plate. This allows the fan to 'freewheel' reducing the load on the engine,
improving fuel consumption and reducing noise generated by the rotation of the fan.
When the radiator temperature increases, the bi-metallic coil reacts and moves the valve, allowing the silicone fluid
to flow into the fluid chamber. The resistance to shear of the silicone fluid creates drag on the drive plate and provides
drive to the body and the fan blades.