Discovery 2. Manual — part 593

STEERING

ADJUSTMENTS

57-21

13. Remove bolt from steering box pipe retaining

clip. Leaving the PAS reservoir oil pipe in place,
release pipe retaining clip and PAS cooler pipe
from steering box, discard the seal.

14. Fit tool LRT-57-041 to steering box housing.
15. Fit seal to PAS oil cooler pipe.
16. Fit PAS cooler pipe to LRT-57-041 align the

retaining clip to pipes and tighten bolt to 24 Nm
(18 lbf.ft).

17. Connect test hoses LRT-57-002 to LRT-57-

041 and tighten unions. Ensure all pipes and
fittings are clear of engine rotating parts.

18. Hang pressure gauge in a safe position under

bonnet.

19. LHD only: Fit turbocharger intercooler feed

pipe and vacuum connection and fit PAS
reservoir to mounting bracket. Fit air intake
hose to turbocharger and air cleaner and
connect multiplug to MAF sensor. The above
parts must be refitted in order to run the
engine.

20. Fill PAS reservoir, connect battery earth lead.

Start engine and allow air to bleed from PAS
system, by turning steering from lock to lock.
Stop engine and check PAS fluid level.

21. Ensure steering system is free from leaks and

maintain maximum fluid level during test.

22. Open the test valve on LRT-57-001 and start

the engine.

23. With the engine at idle and normal running

temperature, slowly turn the steering wheel and
hold on lock.

24. Note reading on pressure gauge.
25. Repeat pressure check on opposite lock, again

noting the reading on the pressure gauge.

26. The test pressure should be between 21 and 62

bar, (300 to 900 lbf/in

2

. Pressure will rise to 62

bar (900 lbf/in

2

) when held on full lock.

27. With the engine at idle, centralise the steering

wheel. Pressure should read 7 bar (100 lbf/in

2

)

or below.

28. Pressure outside the above tolerance indicates

a fault.

29. To determine if fault is in steering pump or

steering rack, close the valve on LRT-57-001
for a maximum of five seconds. Pump damage
may occur if test valve is closed for longer
periods.

30. If the gauge does not register between 75 and

103 bar, (1500 lbf/in

2

) (maximum pump

pressure), the pump is faulty.

31. If maximum pump pressure is obtained,

suspect the steering box.

32. On completion, stop engine, disconnect battery

earth lead and syphon fluid from PAS reservoir.

33. LHD only: Disconnect multiplug from MAF

sensor, remove air intake hose clips and move
hose aside.

34. LHD only: Release PAS reservoir from

mounting, for access to turbocharger
intercooler pipe.Remove vacuum hose from
turbocharger intercooler pipe.Release clips and
disconnect intercooler pipe from turbocharger.

35. Remove test equipment from tool LRT-57-041.
36. Remove bolt and clip from steering box.
37. Release PAS cooler pipe from tool LRT-57-041

and discard seal. leaving PAS reservoir oil pipe
in place, release tool LRT-57-041 from
steering box and discard seal.

STEERING

57-22

ADJUSTMENTS

38. Fit new seal, connect PAS cooler pipe and

tighten union nut to 24 Nm (18 lbf ft).

39. LHD only: Fit turbocharger intercooler feed

pipe and vacuum connection. Fit new seal to air
cleaner. Connect air intake hose and secure
clips. Connect multiplug to MAF sensor.

40. Clean chassis and surrounding area.
41. Fit underbelly panel.

+

EXTERIOR FITTINGS, REPAIRS,

Panel - underbelly.

42. Remove adaptor and hose set from tool LRT-

57-041.

43. Check PAS fluid level.
44. Connect battery earth lead.

Power steering pressure check - V8 LHD
models

$% 57.90.10.01

Check

1. Disconnect battery earth lead.
2. Syphon PAS fluid from reservoir.
3. Raise front of vehicle and support on stands.
4. Turn steering on LH lock.

5. Remove 3 screws securing LH splash shield

and remove shield.

6. Release clip securing PAS pipes.
7. Position absorbent cloth to catch spillage.
8. Position container to collect PAS fluid spillage.

STEERING

ADJUSTMENTS

57-23

9. Release clips and remove air intake hose from

air cleaner housing.

Note: Pre 03 MY air intake hose illustrated.

10. Discard intake 'O' ring and move intake aside

for access.

11. Loosen union securing high pressure pipe to

PAS pump and release pipe.

12. Fit adaptor LRT-57-034A to high pressure port

of PAS pump.

13. Fit adaptor LRT-57-035 to existing high

pressure hose.

14. Fit hose LRT-57-002/3 to each adaptor.
15. Fit pressure gauge LRT-57-005 to test valve

LRT-57-001

16. Connect hoses LRT-57-002/3 to LRT-57-001

and tighten unions.

17. Hang pressure gauge in a safe position under

bonnet.

18. Remove PAS reservoir filler cap, fill to level

indicator and refit cap.

19. Connect battery earth lead.
20. Start engine and allow air to bleed from PAS

system by turning steering from lock to lock.
Stop engine and check PAS fluid level.

21. Ensure steering system and test equipment are

free from leaks.

22. Maintain maximum fluid level during test.
23. Open the test valve on LRT-57-001 and start

the engine.

24. With the engine at idle, slowly turn the steering

wheel and hold on full lock.

25. Note the pressure reading on LRT-57-005.
26. Repeat the pressure check for the opposite full

lock.

27. Test pressure should be between 21 and 62

bar, (300 to 900) psi. Dependant on road
surface.

28. With the engine at idle, centralise the steering

wheel. Pressure should read 7 bar (100 psi) or
below.

29. Pressures outside the above tolerance

indicates a fault.

30. To determine if fault is in steering pump or

steering box, close the valve on LRT-57-001 for
a maximum of 5 seconds. Pump damage may
occur if test valve is closed for longer periods.

31. If gauge does not register between 75 and 103

bar, (1500 psi), (maximum pump pressure), the
pump is faulty.

32. If maximum pump pressure is correct suspect

the steering box.

STEERING

57-24

ADJUSTMENTS

33. On completion stop engine, disconnect battery

earth lead and syphon fluid from PAS reservoir.

34. Remove test equipment from LRT-57-002.
35. Clean PAS pump and pipe union.
36. Fit new 'O' ring to high pressure pipe, align to

PAS pump and tighten union to 25 Nm (18
lbf.ft).

37. Secure PAS pipes in clip.
38. Using new 'O' ring fit intake hose to air cleaner

and secure clips.

39. Remove PAS reservoir filler cap, fill to level

indicator and refit cap.

40. Connect battery earth lead.
41. Start engine and allow air to bleed from PAS

system, by turning steering from lock to lock.

42. Visually check PAS system for leaks.
43. Clean chassis member.
44. Check power steering fluid, if aerated, wait until

fluid is free from bubbles then top-up reservoir
to 'UPPER' level mark.

45. Lower vehicle.
46. Dismantle test equipment.

Power steering pressure check - V8 RHD
models

$% 57.90.10.01

Check

1. Fit gauge and hose LRT-57-005 to valve

assembly LRT-57-001, tighten union.

2. Fit 2 hoses LRT-57-002 to valve assembly

LRT-57-001 and tighten unions.

3. Fit adaptor hoses LRT-57-041 to LRT-57-002

and tighten unions.

4. Disconnect battery earth lead.

5. Remove 5 screws securing front splash shield

to chassis. Remove shield.

6. Clean PAS fluid reservoir around filler cap and

fluid level indicators.