cooling system - td5 LAND ROVER DISCOVERY 2002 Repair Manual

STEERING
57-34 REPAIRS
Steering box - RHD - 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 RH 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.Remove 3 bolts securing intermediate shaft
and universal joint.
9.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.
10.Position container below PAS pipes to catch
fluid spillage.

STEERING
REPAIRS 57-37
10.Lubricate new 'O' rings for PAS pipes with
clean PAS fluid.
11.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).
12.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
13.Remove centralising bolt from steering box.
14.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect battery earth lead.
17.Fit battery cover.
18.Refill cooling system.

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

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

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
Seal - input shaft - steering box
$% 57.10.16
Remove
1.Remove steering box:
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.
2.Secure steering box in vice.
3.Remove circlip and extract oil seal from
steering box. Take care not to damage
surface of the shaft.
Refit
1.Clean oil seal recess and input shaft.
2.Lubricate new seal with clean PAS fluid.
3.Fit seal using LRT-57-503.
4.Fit circlip.
5.Fit steering box.
lFor V8 models:

+ STEERING, REPAIRS, Power
steering box - V8.
lFor LHD diesel models:

+ STEERING, REPAIRS, Power
steering box - LHD - diesel.
lFor RHD diesel models:

+ STEERING, REPAIRS, Steering
box - RHD - diesel.

FRONT SUSPENSION
REPAIRS 60-57
7.Fit pipe clamps to pipe, align clamps to 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 '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.
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.

FRONT SUSPENSION
REPAIRS 60-61
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.
Pipe assembly - valve block to rear
actuator - ACE
$% 60.60.33
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.Raise vehicle on a ramp.
2.Position container under valve block to collect
fluid spillage.
3.Remove 2 bolts securing 2 rear pipe clips to
chassis.

HEATING AND VENTILATION
REPAIRS 80-21
Refit
1.Fit plenum air intake.
2.Fit trim clips and centre bolt securing plenum
air intake to body.
3.Fit rubber spacers and washers to wiper
linkage.
4.Fit locknuts to wiper linkage and tighten to 7
Nm (5.2 lbf.ft).
5.Fit wiper arms to wiper linkage.
6.Fit nuts securing wiper arms to wiper linkage
and tighten to 15 Nm (11 lbf.ft).
7.Fit caps to wiper arms.
8.Fit both windscreen side finishers.

+ EXTERIOR FITTINGS, REPAIRS,
Side finisher - windscreen.
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.

HEATING AND VENTILATION
REPAIRS 80-23
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.
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.

HEATING AND VENTILATION
REPAIRS 80-25
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.
Blower assembly
$% 80.20.12
Remove
1.Remove 4 studs securing toe board and
remove toe board.
2.Remove 4 screws securing glove box, release
catch and remove glove box.
3.Disconnect battery earth lead.

HEATING AND VENTILATION
80-30REPAIRS
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.
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.

AIR CONDITIONING
REPAIRS 82-31
REPAIRS
Compressor - diesel
$% 82.10.20
Remove
1.Remove engine acoustic cover.
2.Depressurise air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
4.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
5.Disconnect multiplug from compressor.
6.Remove 2 bolts securing air conditioning pipes
to compressor and discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
7.Release clips and disconnect top hose from
coolant elbow and heater pipe.
8.Remove 4 bolts securing compressor to
mounting bracket.
9.Remove compressor.Refit
1.Calculate the quantity of refrigerant oil required.

+ GENERAL INFORMATION, Air
Conditioning Compressor Replacement.
2.Position compressor to mounting bracket and
tighten bolts to 25 Nm (18 lbf.ft).
3.Remove caps from compressor and pipe
connections.
4.Clean compressor and pipe connections.
5.Lubricate new 'O'rings with refrigerant oil and
fit to compressor.
6.Position A/C pipes to compressor and tighten
bolts to 10 Nm (7 lbf.ft) .
7.Connect multiplug to compressor.
8.Position top hose and secure with clips.
9.Refill cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
10.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
11.Recharge air conditioning system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
12.Fit engine acoustic cover.

AIR CONDITIONING
REPAIRS 82-33
Fan - condenser
$% 82.15.01
Remove
1.Remove front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
2.Remove 2 bolts securing bonnet platform RH
support stay.
3.Remove support stay.
4.Disconnect multiplug from condenser cooling
fan motor.
5.Remove 4 screws securing cooling fan cowl to
mounting bracket.
6.Remove cooling fan assembly and collect
spacing washers.
Refit
1.Fit condenser fan.
2.Fit spacing washers between fan cowl and
mounting bracket and secure with screws.
3.Connect multiplug to motor.
4.Fit bonnet platform support stay and secure
with bolts.
5.Fit front grille.

+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY.
Condenser
$% 82.15.07
Remove
1.Recover refrigerant from A/C system.

+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Remove radiator.
l

+ COOLING SYSTEM - Td5,
REPAIRS, Radiator.
l

+ COOLING SYSTEM - V8,
REPAIRS, Radiator.
3.Disconnect multiplug from dual pressure
switch.
4.Remove bolt securing evaporator pipe to
condenser.
5.Disconnect evaporator pipe from condenser
and discard 'O' ring.
6.Remove bolt securing evaporator pipe to
receiver drier.
7.Disconnect evaporator pipe from receiver drier
and discard 'O' ring.
CAUTION: Always fit plugs to open
connections to prevent contamination.