Range Rover : cooling system

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Draining WARNING: Do not remove the expansion tank filler cap when the engine is hot because the cooling system is Pressurized and personal scalding could result.

Published : Wednesday, October 12, 2011
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 1 9 8 7 C O O L A N T Drain and refill D r a i n i n g W A R N I N G : D o n o t r e m o v e t h e e x p a n s i o n t a n k f i l l e r c a p w h e n t h e e n g i n e i s h o t b e c a u s e t h e c o o l i n g s y s t e m i s P r e s s u r i z e d a n d p e r s o n a l scalding could result. 1. Remove the expansion tank filler cap by first turning it counter -clockwise a quarter of a turn to allow pressure to escape, then turn it further in the same direction and lift off.
2. Remove the radiator filler plug and washer to assist drainage.
COOLING SYSTEM 3. Disconnect the radiator bottom hose and allow the coolant to drain into a suitable container. Use a clean container if the coolant solution is to be reused. Reconnect the bottom hose after draining and tighten the hose clamp.
4. Remove the engine drain plugs, one each side of the cylinder block, beneath the exhaust manifolds. Allow the coolant to drain and refit the plugs.
S e e t h e f o l l o w i n g c o o l a n t r e q u i r e m e n t s b e f o r e refilling the system. C o n t i n u e d
REVISED: 87
COOLING SYSTEM
Coolant requirements Frost precautions and engine protection. The engine cooling system MUST ALWAYS be filled a n d t o p p e d - u p w i t h a s o l u t i o n o f w a t e r a n d anti-freeze, winter and summer. NEVER use water alone as this may corrode the aluminiun alloy. C A U T I O N : D o n o t u s e s a l t w a t e r o t h e r w i s e corrosion will occur. ln certain territories where the only available natural water supply has some salt content use only rain or distilled water. Recommended solutions A n t i - f r e e z e : U n i v e r s a l a n t i - f r e e z e o r p e r m a n e n t 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 w i l l p r o v i d e a d e q u a t e p r o t e c t i o n f o r t w o y e a r s provided that the specific gravity of the coolant is checked before the onset of the second winter and topped-up with new anti-freeze as required. Vehicles leaving the factory have the cooling system filled with 50% anti-freeze and 50% water mixture. This gives protection against frost down to minus 3 6 ° C ( m i n u s 3 3 ° F ) . V e h i c l e s s o f i l l e d c a n b e identified by a label affixed to the radiator. N O T E : S h o u l d a m b i e n t t e m p e r a t u r e s b e b e l o w t h a t s t a t e d a b o v e r e f e r t o A n t i - F r e e z e D a t a i n Recommended Lubricants, Fluids and Capacities in Section OS. instructions in the chart must be s t r i c t l y a d h e r e d t o b e f o r e d r i v i n g t h e v e h i c l e away. A f t e r t h e s e c o n d w i n t e r t h e s y s t e m s h o u l d b e drained and thoroughly flushed. Before adding new anti-freeze examine all joints and replace defective hoses to make sure that the system is leakproof. S e e t h e ‘ R e c o m m e n d e d L u b r i c a n t s F l u i d s a n d Capacities’, Section 09, for protection quantities.
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REVISED: 
1987
Refilling 5. Pour 4.5 litre gall) of water into the radiator. 6. Add the recommended quantity of anti-freeze. 7 . T o p - u p t h e r a d i a t o r w i t h w a t e r , r e f i t t h e radiator filler plug and washer and tighten. 8. Add water to the expansion tank, up to the ‘WATER LEVEL’ plate. NOTE: The water level plate on later models has been deleted from the expansion tank, therefore t h e c o o l a n t s h o u l d b e f i l l e d t o t h e t o p o f t h e sensor float which is approximately 1.00 inch mm) below the filler neck 9. Fit the expansion tank filler cap.
R u n t h e e n g i n e u n t i l n o r m a l o p e r a t i n g temperature is attained, that is, thermostat open. A l l o w t h e e n g i n e t o c o o l , t h e n c h e c k t h e coolant level and top-up if necessary.
 87
 
   
COOLING SYSTEM  EXPANSION TANK COOLANT LEVEL SENSOR Remove and refit Remove and refit Removing Removing W A R N I N G : D o n o t r e m o v e t h e e x p a n s i o n t a n k W A R N I N G : D o n o t r e m o v e t h e e x p a n s i o n t a n k f i l l e r c a p w h e n t h e e n g i n e i s h o t b e c a u s e t h e f i l l e r c a p w h e n t h e e n g i n e i s h o t b e c a u s e t h e c o o l i n g s y s t e m i s p r e s s u r i z e d a n d p e r s o n a l c o o l i n g s y s t e m i s p r e s s u r i z e d a n d p e r s o n a l scalding could result. scalding could result. Remove the expansion tank filler cap by first 1. Disconnect the multi-plug from the sensor. turning it counter -clockwise a quarter of a 2. Remove the expansion tank filler cap by first turn to allow pressure to escape, then turn it turning it counter -clockwise a quarter of a further in the same direction and lift off. turn to allow pressure to escape, then turn it 2 . Disconnect the hose to the radiator. further in the same direction and lift off. Disconnect the multi-plug to the coolant level 3. Release the retaining nut and withdraw the sensor. sensor from the expansion tank. 4 . Remove the pinch bolt.
5. Lift out the expansion tank. R e f i t t i n g 6. Reverse 1 to 5. 7. Replenish the cooling system. 8. Check for leaks around all hose connections.
R e f i t t i n g 4 . Reverse the removal instructions. 5 . S t a r t e n g i n e a n d r u n u n t i l n o r m a l r u n n i n g temperature is attained, thermostat open, check for coolant leaks around the sensor.
 
FAN BELT VISCOUS COUPLING, FAN BLADES, PULLEY AND FAN COWL Check and adjust tension, 1 and 5 to 6 Viscous coupling-remove and refit 1 to 5 Remove and refit, 1 to 6 Fan blades-remove and refit 1 to 5 and Removing Fan cowl-remove and refit 1 to 4 W A R N I N G : D i s c o n n e c t t h e b a t t e r y n e g a t i v e t e r m i n a l t o p r e v e n t t h e e n g i n e b e i n g s t a r t e d Fan pulley-remove and refit 1 to 7 before removing or adjusting drive belts. Removing 1. Loosen the idler pulley pivot bolt. 2. Pivot the idler pulley inwards. W A R N I N G : Disconnect t h e b a t t e r y n e g a t i v e 3. Lift off the fan belt. t e r m i n a l t o p r e v e n t t h e e n g i n e b e i n g s t a r t e d before removing or adjusting drive belts. 1. Loosen the nut securing the viscous coupling and fan blade assembly to the water pump . shaft. NOTE: The nut securing the viscous unit to t h e w a t e r p u m p h a s a l e f t h a n d t h r e a d , t o r e l e a s e t h e n u t , t u r n i n a c l o c k w i s e direction when viewed from the front of the viscous unit. 2. Remove the four fan cowl fixings and lift the cowl out of its lower mountings.
R e f i t t i n g 4 . Locate the fan belt on the pulleys. 5 . Adjust the fan belt using the idler pulley to give 4 to 6 mm (0.19 to 0.25 in) free movement when checked midway between the fan and crankshaft pulleys by hand. 6 . Tighten the idler pulley pivot bolt and check the adjustment.  Remove the viscous coupling securing nut and N O T E : R e - c h e c k t h e b e l t a d j u s t m e n t a f t e r withdraw the assembly. approximately 1 5 0 0 k m ( 1 , 0 0 0 m i l e s ) 4. Remove the fan cowl, if necessary. running when a new belt has been fitted. 5 . R e m o v e t h e f a n b l a d e s f r o m t h e v i s c o u s coupling. if necessary. 6. Remove the fan belt and, if fitted, the compressor belt.  Remove the pulley fixings and withdraw the pulley.
 1987
Refitting Reverse the above procedure, ensuring the fan blades are fitted correctly. The fan is marked FRONT and should be fitted with the word FRONT closest to the radiator. See Torque  06 for correct torque figure. Adjust the fan belt and compressor belt.
COOLING SYSTEM
RADIATOR Remove and refit Removing Drain the cooling system. 2 . Remove the fan blades. Remove the fan cowl. 4 . Disconnect the top hose from the radiator. 5 . Disconnect the hose to the expansion tank at the radiator.
6. Disconnect the hose to the thermostat elbow at the intake manifold. 7. Remove the fixings trom each side of the r a d i a t o r .
8 . W i t h d r a w t h e r a d i a t o r l i f t i n g f r o m i t s  Check the condition of the rubber  pads. R e f i t t i n g 9. Reverse I  to noting the assembly order of the radiator side fixings and ensuring that the radiator sealing strips are located and secure. 1 0 . C h e c k c o o l a n t l e a k s a r o u n d a l l h o s e connections. REVISED: JULY 88 5
T H E R M O S T A T T e s t i n g Remove and refit 6. Note that the rating of the thermostat is 88°C ( 1 9 0 ° F ) . P l a c e t h e t h e r m o s t a t i n a s u i t a b l e T e s t container half full of water. Heat the water and o b s e r v e t h e t e m p e r a t u r e a t w h i c h t h e Removing thermostat opens. Should the thermostat open between 85°C (185°F) and 89°C (192°F) the 1. Partially drain the cooling system, until coolant unit is operating satisfactorily. level is below thermostat housing. 2 . D i s c o n n e c t t h e h o s e f r o m t h e t h e r m o s t a t R e f i t t i n g . housing. 3. Disconnect the electrical connections to the 7 . Insert the thermostat with the jiggle pin/vent water temperature switch. hole uppermost o’clock position). 8 . Using a new joint washer, fit the outlet elbow and tighten to the correct torque, see Torque values-Section 06. 9 . Reverse 1 to 3. 1 0 . C h e c k f o r c o o l a n t l e a k s a r o u n d a l l h o s e connections and joint faces.
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4. Remove the outlet elbow. 5. Withdraw the thermostat.
REVISED: JULY 88
R O V E R
WATER PUMP Remove and refit Removing W A R N I N G : D i s c o n n e c t t h e b a t t e r y n e g a t i v e t e r m i n a l t o p r e v e n t t h e e n g i n e b e i n g s t a r t e d before removing or adjusting drive belts. 1. Drain the engine cooling system. -2. Remove the fan belt, power steering pump and compressor belt. 3. Remove the fan blades and pulley. 4 . D i s c o n n e c t t h e i n l e t h o s e f r o m t h e w a t e r 5. Release the alternator adjusting link and the power Steering pump fixings. 6. Remove the remaining water pump bolts. 7. Remove the water pump and joint washer.
COOLING SYSTEM
R e f i t t i n g 8. Lightly grease a new joint washer and place it in position on the timing cover.
9 . Clean the threads of the four long bolts and coat with Loctite 572 thread lubricant-sealant. 1 0 . Locate the water pump in position. 1 1 . L o c a t e t h e a l t e r n a t o r a d j u s t i n g l i n k a n d power-steering pump bracket. 1 2 . Leave the alternator adjusting lin and tighten the remaining water pump housing bolts evenly and to the correct torque, see Torque values-Section 06. 1 3 . Connect the inlet hose to the water pump. 1 4 . Fit the fan pulley. 1 5 . Fit and adjust the fan belt, power steering pump belt and compressor belt. Fit the fan blade assembly. 1 7 . Refill the cooling system. 18. C h e c k f o r c o o l a n t l e a k s a r o u n d a l l h o s e connections and joint faces.
 
  COOLING SYSTEM
5YMPTOM
4. EXTERNAL LEAKAGE
B INTERNAL LEAKAGE
C WATER LOSS
D POOR CIRCULATION
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COOLING SYSTEM FAULT DIAGNOSIS
POSSIBLE CAUSE
Loose hose clamps Defective rubber hose Damaged radiator seams Excessive wear in the water Loose core plugs Damaged gaskets Leaks at the heater connections. Leak at the water temperature transmitter
Defective cylinder head gasket 2. Cracked cylinder wall 3. Loose cylinder head
B o i l i n g Internal or external leakage Restricted radiator or inoperative thermostat
Restriction in system Insufficient coolant Inoperative water pump Loose fan belt 5. Inoperative thermostat
CURE
Tighten Replace Rectify Replace Replace Replace Rectify Tighten the transmitter
R O V E R
Replace. Check engine oil for contamination and refill if necessary Replace cylinder block Tighten. Check engine bolts for oil contamination and refill as necessary
Ascertain the cause of engine overheating and correct as necessary See items A and B Flush radiator or replace the thermostat as necessary.
Check hoses for crimps, reverse-flush the radiator, and clear the system of rust and s l u d g e Top-up coolant Replace Adjust Replace
 
ROVER
 CORROSION
 OVERHEATING
G OVERCOOLING
POSSIBLE CAUSE
Excessive impurity in the waler 2 . Infrequent flushingand draining of system 3. Incorrect anti-freeze mixtures
Poor circulation 2 . Dirty oil and sludge in engine. 3 . Radiator fins choked with chaff, mud etc. 4 . Incorrect ignition timing 5 . Insufficient coolant 6. Low oil level 7. Choked or damaged 8 . Dragging brakes 9 . Overloading vehicle 1 0 . Driving in heavy sand or mud 11. Engine labouring on gradients 12. Low gear work  Excessive engine idling 14. Inaccurate temperature gauge  Defective thermostat
Defective thermostat 2. Inaccurate temperature gauge
CURE
COOLING SYSTEM
1.  only soft, clean water together with correct anti-freeze mixture. 2. The cooling system should be drained and flushed thoroughly at least once a year. 3 . Certain anti-freeze solutions have a corrosive effect on parts of the cooling. system. Only recommended solutions should be used.
1. See item D 2 . R e f i l l 3 .  air pressure from the engine side of the radiator and clean out passages thoroughly 4 . Check using electronic equipment 5 . S e e i t e m D 6 . Replenish 7 . Rectify or replace exhaust pipe or muffle 8. Adjust brakes 9 . In the hands of the operator 10. In the hands of the operator Il. In the hands of the operator In the hands of the operator  In the hands of the operator  Check or replace 15. Check or replace
I. Check or replace 2 . Check or replace
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COOLING SYSTEM
ROVER COOLING SYSTEM 1989 model year. The 3.9 engine has a revised ‘partial flow’ type cooling system. A new radiator incorporates oil coolers in both end tanks left hand side, transmission oil cooler right hand engine oil cooler. A supplementary transmission oil cooler is still fitted in front of the radiator and condenser fans. The transmission oil high temperature warning light sensor is now fitted under the hood adjacent to the radiator end tank. C O O L A N T Drain and refill 3. Disconnect the bottom hose at its junction with the radiator and allow the coolant to D r a i n i n g drain into a suitable Ensure that the container is clean if the coolant solution is to W A R N I N G : D o n o t r e m o v e t h e e x p a n s i o n t a n k be re-used. Reconnect the bottom hose after f i l l e r c a p w h e n t h e e n g i n e i s h o t , b e c a u s e t h e draining and re-tighten the hose clamp. c o o l i n g s y s t e m i s p r e s s u r i s e d a n d p e r s o n a l scalding could result. 1. Remove the expansion tank filler cap by first turning it counter-clockwise a quarter of a turn to allow pressure to escape, turn it further in the same direction and lift off.
2. Remove the radiator filler plug and ring to assist drainage.
4. Remove the engine drain plugs, one each side of the cylinder block, beneath the exhaust manifolds. Allow the coolant to drain, refit and tighten the plugs.
C o n t i n u e d
ADDITION: SEPT. 88 REVISED: DEC 88
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