cooling system LAND ROVER DISCOVERY 2002 Manual PDF

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

COOLING SYSTEM - TD5
26-1-14 ADJUSTMENTS

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.

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.

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.

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