Land Rover Defender V8i Workshop Supplement Rover Manual

							26COOLING SYSTEM
2
REPAIR
5.Position toolLRT-12-093to hold coolant pump
pulley.
6.Loosen viscous coupling nut using tool
LRT-12-094.
7.Remove toolLRT-12-093.
8.Remove viscous coupling assembly.
Do not carry out further dismantling if component
is removed for access only.
9.Remove 4 Allen screws securing fan blades to
coupling.
10.Remove fan blades from coupling.
Refit
11.Clean mating faces of fan blades and coupling.
12.Fit fan blades to coupling and secure with Allen
screws.
13.Position coupling assembly and start tightening
nut.
14.Position toolLRT-12-093to hold pulley.
15.Tighten viscous coupling assembly nut using
toolLRT-12-094.
16.Remove tools.
17.Fit fan upper cowl and secure with clips.
18.Secure coolant hoses to fan upper cowl and
secure with clips.
19.Align fan cowl fixings to upper mounting brackets
and secure with screws.
20.Reconnect battery negative lead. 
						

							COOLING SYSTEM
3
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See Adjustment, drain
and refill
3.Remove 8 screws securing front grille to body.
4.Remove front grille.
5.Remove 4 bolts securing radiator top mountings
to bonnet locking panel and collect nuts.
6.Remove radiator top mountings.
7.Remove fan cowl upper mounting brackets.
8.Loosen clip and disconnect top hose from
radiator.
9.Remove 2 clips securing fan cowl to radiator.
10.Remove fan cowl. 
						

							26COOLING SYSTEM
4
REPAIR
11.Loosen clip and disconnect throttle body to
radiator hose.
12.Loosen clip and disconnect expansion tank to
radiator hose.
13.Position container beneath engine oil cooler pipe
unions.
14.Loosen engine oil cooler pipes and disconnect
from radiator.
15.Remove and discard O rings from oil cooler
pipes.
16.Plug oil cooler pipe connections.
17.Loosen clip and disconnect bottom hose from
radiator.
18.Release radiator from lower mounting rubbers
and remove radiator.Refit
19.Fit radiator and secure to lower mounting
rubbers.
NOTE: Ensure condenser lower mounting
brackets are located to radiator lower
mounting brackets.
20.Connect bottom hose to radiator and secure with
clip.
21.Remove plugs from engine oil cooler pipe
connections.
22.Clean oil cooler pipe connections.
23.Lubricate NEW O rings with clean engine oil
and fit to pipes.
24.Connect oil cooler pipes to radiator and tighten
unions to
30 Nm (22 lbf.ft).
25.Remove container.
26.Connect expansion tank hose to radiator and
tighten clip.
27.Connect throttle body hose to radiator and
tighten clip.
28.Fit fan cowl to radiator.
29.Fit fan cowl lower retaining clips.
30.Connect top hose to radiator and tighten clip.
31.Fit fan upper cowl and secure with clips.
32.Fit fan cowl upper mounting brackets.
33.Fit radiator top mountings and secure with
screws and bolts.
34.Fit front grille and secure with screws.
35.Refill cooling system.
See Adjustment, drain
and refill
36.Reconnect battery negative lead.
37.Top-up engine oil. 
						

							COOLING SYSTEM
5
REPAIR THERMOSTAT
Service repair no - 26.45.01
Remove
1.Disconnect battery negative lead.
2.Drain cooling system.
See Adjustment, drain
and refill
3.Loosen clip and disconnect radiator top hose
from coolant outlet elbow.
4.Remove 2 bolts securing coolant outlet elbow to
engine.
5.Remove coolant outlet elbow and collect gasket.
6.Remove thermostat.
Refit
7.Fit thermostat ensuring jiggle pin/vent hole is
uppermost.
8.Fit coolant outlet elbow with NEW gasket.
9.Fit and tighten bolts securing coolant outlet
elbow to
28 Nm (21 lbf.ft).
10.Connect radiator top hose to coolant outlet
elbow tighten clip.
11.Refill cooling system.
See Adjustment, drain
and refill
12.Reconnect battery negative lead.COOLANT PUMP
Service repair no - 26.50.01
Remove
1.Drain cooling system.
See Adjustment, drain
and refill
2.Loosen coolant pump pulley bolts.
3.Release auxillary drive belt tension by turning
tensioner clockwise.
4.With tension released, remove belt from
alternator pulley.
5.Remove drive belt.
NOTE: If belt is to be refitted, mark
direction of rotation.
6.Remove bolts securing coolant pump pulley.
7.Remove coolant pump pulley. 
						

							26COOLING SYSTEM
6
REPAIR
8.Noting their fitted positions, remove 9 bolts
securing coolant pump.
9.Remove coolant pump.
10.Remove and discard gasket.
Refit
11.Clean coolant pump and timing cover mating
faces.
12.Lightly grease NEW gasket and position to
timing cover.
13.Clean threads of all long bolts and coat with
Loctite 572 thread sealant.
14.Position coolant pump, fit bolts and tighten to
28
Nm (21 lbf.ft).
15.Fit coolant pump pulley, fit bolts but do not
tighten.
16.Clean auxillary drive belt pulley grooves and
inspect for damage.
17.Fit belt to pulleys.
18.Turn drive belt tensioner clockwise and engage
belt on alternator pulley.
19.Release drive belt tensioner.
20.Tighten coolant pump pulley bolts.
21.Refill cooling system.
See Adjustment, drain
and refill 
						

							COOLING SYSTEM
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Nm lbf.ft
Oil cooler pipes 30................................................................ 22
Radiator filler plug (plastic) 6............................................... 4.5
Coolant pump bolts 28.......................................................... 21
Coolant outlet elbow bolts 28................................................ 21 
						

							30 - MANIFOLD AND EXHAUST SYSTEM
CONTENTS
Page
DESCRIPTION AND OPERATION
CATALYTIC CONVERTERS - V8i 1.......................................................................
REPAIR
INTERMEDIATE PIPE 1.........................................................................................
TAIL PIPE 1............................................................................................................
INLET MANIFOLD GASKET 2................................................................................
SPECIFICATIONS, TORQUE
TORQUE VALUES 1............................................................................................... 
						

							MANIFOLD AND EXHAUST SYSTEM
1
DESCRIPTION AND OPERATION CATALYTIC CONVERTERS - V8i
Description
Catalytic converters which form part of the engine
emission control system, are designed to clean the
exhaust gases, by chemically converting pollutant
elements in the exhaust to gases less harmful to the
environment.
1.Catalysts
2.Oxygen sensors
The front section of the exhaust system from each
cylinder bank contain the ceramic elements of the
catalytic converters. The oxygen sensors, which
transmit information to the fuel ECM for control of the
mixture, are located in the exhaust down pipes.
The Hydrocarbons (HC), Nitogen oxides (NO
x) and
Carbon monoxide (CO) emitted by the engine react
with the catalytic element and exhaust temperature to
convert the toxic gas, into Nitrogen (N2), Carbon
dioxide (CO
2) and water vapour (H2O).
The sophisticated closed loop control system ensures
that mixture is always kept at the optimum level for
peak catalyst efficiency. Also, the advanced On Board
Diagnostics ensure that any faults likely to cause
damage to the catalyst are indicated to the driver.However, should the engine be supplied with a rich
mixture causing high CO in the exhaust gas, the
ceramic element will become coated and the useful
life of the catalyst reduced. If the mixture is too weak,
excess oxygen in the exhaust gas will cause the
catalysts to burn out. Similarly, should a cylinder
misfire occur, the unburnt fuel and unburnt oxygen
can cause a catalyst burn out.
CAUTION: The catalyst matrices are fragile
ceramic honeycombs which can become
damaged if roughly treated. Do not use a
hammer or mallet when working on the exhaust
system.