Land Rover Range Rover Classic Workshop 1995 Rover Manual

							26COOLING SYSTEM RANGE ROVER
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REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing drive belts.
1.Drain engine cooling system.
See Adjustment,
Coolant
2.Remove top hose radiator to thermostat.
3.Remove top hose intercooler to induction
manifold.
4.Slacken water pump and power steering pump
pully retaining bolts.
5.Remove drive belt.
6.Remove centre nut from belt tensioner.
7.Manoeuvre pulley upwards and withdraw
tensioner from retaining stud.
8.Disconnect hose thermostat to bottom hose,
release hose from clip on water pump and move
aside.
9.Remove water pump pulley.
10.Remove power steering pump pulley.
11.Remove 8 bolts securing water pump, noting
location of 3 through bolts.
12.Withdraw pump and gasket, clean all gasket
material from mating surfaces.
Refit
13.Refit water pump in reverse order to removal
using new gasket.RADIATOR
Service repair no - 26.40.01
Remove
1.Drain cooling system.
See Adjustment,
Coolant
2.Disconnect radiator top hose.
3.Remove fan blade assembly.
4.Remove cowl.
5.Disconnect engine oil cooler connections and
turbo intercooler connections from radiator ends.
NOTE: Oil spillage will occur when
connections are loosened. Blank off
exposed oil connections.
6.Disconnect expansion tank bleed hose from
radiator.
7.Remove radiator securing brackets from each
side.
8.Remove radiator unit by lifting from its location.
Check condition of rubber mounting pads.
Refit
9.Check radiator sealing strips are securely
located.
10.Transfer oil cooler adaptors if fitting new radiator.
11.Reverse removal procedure. Tighten oil cooler
connections to
30 Nm,before fitting fan blades
and cowl.
12.Check all connections for leaks. 
						

							V8i
1
DESCRIPTION AND OPERATION ENGINE COOLING
Description
The V8i engine uses a pressurised cooling system
and cross flow radiator which is supplied from a
separate header tank. The coolant radiator also
incorporates a section at the left hand end for cooling
the transmission oil and a section at the other end for
cooling the engine oil.The belt driven viscous fan and centrifugal water
pump is located in the engine front cover with ports for
circulation of coolant to both banks of cylinders and
cylinder heads. Coolant returns to the top of the
radiator via ports in the inlet manifold where the
thermostat is mounted horizontally.
Coolant also circulates through the vehicle heating
system and is used to heat air entering the inlet
manifold plenum chamber.
Coolant circulation (engine hot)
1. Cross flow radiator
2. Header tank
3. Viscous fan and water pump
4. Heater pipes
5. Plenum chamber connection
6. Thermostat 
						

							26COOLING SYSTEM RANGE ROVER
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DESCRIPTION AND OPERATION COOLANT CIRCULATION
Operation
When the engine is started from cold the thermostat
prevents any coolant circulation through the radiator
by closing off the top hose. During the engine warm
up period, the water pump, pumps coolant around the
cylinders to the rear of the cylinder block along the
main galleries in both cylinder banks. At the rear of
the cylinder block the coolant rises through a large
port in each cylinder head/block joint face, and then
flows forward to connect with ports at the front of the
inlet manifold. From the manifold the coolant is carried
by an external pipe to the heater unit and from the
heater through another external pipe to the pump
inlet.The coolant circulation through the cylinder block and
heads, does not change when normal running
temperature is reached and the thermostat opens. But
with the thermostat open, coolant flows through the
top hose to the radiator where it is cooled and drawn
back into the pump via the bottom hose. 
						

							V8i
3
DESCRIPTION AND OPERATION Plenum chamber heating
Air entering the plenum chamber is heated by a flow
of coolant from the inlet manifold which returns
through a long hose, to the top right corner of the
radiator.
1. Hot water supply
2. Cold return to radiatorVISCOUS FAN
Description
The viscous drive unit for the engine cooling fan,
provides a means of controlling the speed of the fan
relative to the running temperature of the engine. The
viscous unit is a type of fluid coupling, which drives
the fan blades through the medium of a special
silicone fluid injected into the unit during
manufacture.
1. Drive in from water pump spindle
2. Drive out to fan blades
3. Bi-metal 
						

							26COOLING SYSTEM RANGE ROVER
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DESCRIPTION AND OPERATION Operation
The viscous unit consists of two principal components:
An inner member 1 which is secured to water pump
spindle and is driven by the fan belt.
An outer member 2 which has the fan blades
attached, houses the working parts and is driven
through the medium of the viscous fluid.
The inner and outer members have interlocking
annular grooves machined in each, with a small
running clearance 3 to allow the silicone fluid to
circulate through the valve plate 4.
The unit also contains a valve 5 which is controlled by
an external bi-metal thermostat 6.
Starting engine from cold
During the time the engine is at rest the silicone fluid
drains down, half filling chambers A and B. Thus when
the engine is first started sufficient fluid is present in
chamber A to provide a positive drive between the
members, as is evident by the initial noise of the fan.
However within a very short period of time, after
starting the engine, the fan speed and noise will
decline indicating that the fluid is being centrifuged
into chamber B (as seen in RR3757M) causing the
drive to slip.
Viscous unit slipping (Engine at normal running
temperature)
1. Inner member (drive in fast)
2. Outer member (drive out slow)
3. Running clearance
4. Valve plate
5. Valve (closed)
6. Bi-metal
7. Fluid seals
8. Ball race
A. Fluid chamber
B. Fluid chamber
If the engine speed is increased the degree of slip will
also increase to limit the maximum fan speed. 
						

							V8i
5
DESCRIPTION AND OPERATION Hot conditions
When operating in high ambient temperatures or
when stationary in traffic, the bi-metal thermostat will
operate and open the valve port between chambers A
and B.
Opening the valve (as shown in RR3758M) allows the
fluid to circulate between the two members, causing
the unit to couple, thus increasing the fan speed and
cooling effect.
Viscous unit coupled (Hot running conditions)
Bi-metal expanded, valve (open) 
						

							V8i
1
FAULT DIAGNOSIS ENGINE OVERHEATING
Before conducting any cooling system diagnosis:
See
Description and operation, Engine Cooling
1.Is coolant level correct?
NO - Allow engine to cool, top up level to
expansion tank seam.
YES - Continue.
2.Is drive belt tension correct?
NO -
See ENGINE, Repair, Drive Belt -
Check Tension
YES - Continue.
3.Is ignition timing correct?
NO -
See ELECTRICAL, Adjustment,
Ignition Timing
YES - Continue.
4.Is coolant in radiator frozen?
YES - Slowly thaw and drain system.
See
Adjustment, Coolant Requirements
NO - Continue.
5.Is air flow through radiator restricted or blocked?
YES - Apply air pressure from engine side of
radiator to clear obstruction.
NO - Continue.
6.Are there any external leaks, from water pump,
engine gaskets or the heater unit?
YES - Investigate and rectify.
See Adjustment,
Coolant Requirements
NO - Continue.
7.Are fan blades fitted correct way round, concave
side towards engine?
NO - Rectify.
YES - Continue.8.Is viscous unit operating correctly?
See
Description and operation, Viscous Fan
NO - Renew.See Repair, Viscous
Coupling, Fan Blades, Pulley and Fan
Cowl
YES - Carry out a pressure test on radiator cap
and system. Check thermostat type,
operation and correct fitting
See Repair,
Thermostat
If pressure test leads you to suspect coolant
leakage across gaskets, go to check 11,
otherwise: Continue.
9.Are the air conditioning fans operating correctly?
See Electrical Trouble Shooting Manual.K5
NO - Rectify.
YES - Continue.
10.Is temperature sender and gauge giving
accurate readings?
NO - Substitute parts and compare readings.
YES - Continue.
11.Carry out cylinder pressure test to determine if
pressure is leaking into cooling system causing
over pressurising and loss of coolant.
If problem is not diagnosed, check the coolant system
for engine oil contamination and engine lubrication
system for coolant contamination.
If the coolant only, or both systems are contaminated,
suspect cylinder head gaskets or radiator.
If only the lubrication stystem is contaminated with
coolant, suspect inlet manifold or front cover gaskets. 
						

							26COOLING SYSTEM RANGE ROVER
2
FAULT DIAGNOSIS ENGINE RUNS COLD
Before conducting any cooling system diagnosis:
See
Description and operation, Engine cooling
1.Check operation of viscous unit.See
Description and operation, Viscous Fan
Is viscous unit operating correctly?
NO -
See Repair, Viscous coupling, fan
blades, pulley and fan cowl
YES - Continue.
2.Is thermostat correct type and operating?
See
Repair, Thermostat
If problem is not diagnosed: Continue.
3.Are the air conditioning fans operating
continuously?
YES -
See Electrical Troubleshooting Manual
NO - Continue.
4.Is temperature sender and gauge giving
accurate readings? Substitute parts and
compare readings. If problem is not diagnosed
repeat tests, starting at 1. 
						

							V8i
1
ADJUSTMENT COOLANT REQUIREMENTS
Frost precautions and engine protection.
Cooling systemMUST ALWAYSbe filled and
topped-up with solution of water and anti-freeze,
winter and summer.NEVERuse water alone, this
may corrode aluminium alloy.
CAUTION: Do not use salt water otherwise
corrosion will occur. In certain territories
where only available natural water supply
has some salt content use only rain or distilled
water.
Recommended solutions
Anti-freeze:Universal anti-freeze or permanent type
ethylene base, without methanol, containing a suitable
inhibitor for aluminium engines and engine parts.
Use one part of anti-freeze to one part of water.
Anti-freeze can remain in the cooling system and will
provide adequate protection for two years provided
that specific gravity of coolant is checked before onset
of second winter and topped-up with new anti-freeze
as required.
Vehicles leaving factory have cooling system filled
with 50% solution of anti-freeze and water. This gives
protection against frost down to minus 36ÊC (minus
33ÊF). Vehicles so filled are identified by a label
affixed to radiator.
NOTE: Should ambient temperatures be
below that stated above refer to
Anti-Freeze Data in Recommended
Lubricants, Fluids and Capacities in Section 09.
Instructions in chart must be strictly adhered to
before driving vehicle.
After the second winter the system should be drained
and thoroughly flushed. Before adding new anti-freeze
examine all joints and replace defective hoses to
make sure that the system is leakproof.
See the Recommended Lubricants Fluids and
Capacities for protection quantities.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
COOLANT
Service repair no - 26.10.01
Draining
WARNING: Do not remove expansion tank
filler cap when engine is hot. The cooling
system is pressurised and personal
scalding could result.
See coolant requirements before refilling system.
1.Remove expansion tank filler cap by slowly
turning it anti-clockwise, pause to allow pressure
to escape. Continue turning it in same direction
and remove.
2.Remove radiator filler plug and O ring to assist
drainage. 
						

							26COOLING SYSTEM RANGE ROVER
2
ADJUSTMENT 3.Disconnect bottom hose from radiator. Drain
coolant into a clean container. Reconnect bottom
hose, re-tighten hose clamp.
NOTE: It is not possible to drain all coolant
retained in heater system. It is not
desirable to flush through system, after
draining.
4.Remove engine drain plugs, one each side of
cylinder block, beneath exhaust manifolds. Drain
coolant, refit and tighten plugs.
5.Pour correct solution of water and anti-freeze
into expansion tank until radiator is full.
6.Start engine, run it until normal operating
temperature is attained, topping up as
necessary.
7.Refit radiator filler plug and O ring, with new O
ring if required. Tighten to
6 Nm.
8.Fit expansion tank filler cap.
9.Allow engine to cool, check coolant level. Finally
top up expansion tank until level reaches seam
of expansion tank.