Discovery 2. Manual — part 515
COOLING SYSTEM - TD5
ADJUSTMENTS 26-1-13
ADJUSTMENTS
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.
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.
ADJUSTMENTS, Drain and refill.
2. Remove 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.
10. Refill cooling system.
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