1995 LAND ROVER DISCOVERY cooling

26COOLING SYSTEM
6
REPAIR WATER PUMP
Service repair no - 26.50.01
Remove
WARNING: Disconnect battery negative
terminal to prevent engine being started
before removing or adjusting drive belts.
1.Drain engine cooling system.
See Adjustment,
Coolant
2.Remove fan blades and pulley.See Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
3.Disconnect inlet hose from water pump.
4.Remove water pump bolts.
5.Remove water pump and joint washer.
Refit
6.Lightly grease new joint washer, position on
timing cover.
7.Clean threads of all long bolts and coat with
Loctite 572 thread lubricant-sealant.
8.Locate water pump in position. Tighten
remaining water pump housing bolts evenly to
28 Nm.
9.Reverse removal procedure. 1 to 3.
10.Check for coolant leaks around all hose
connections and joint faces.

Mpi
1
REPAIR COOLANT PUMP
Service repair no - 26.50.01
Remove
1.Position drain tin below coolant pump hose.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Release clip and disconnect hose from coolant
pump housing cover.
3.Remove 5 bolts securing housing cover.
4.Remove housing cover.
5.Remove coolant pump from housing.
6.Discard 3 sealing rings.
Refit
7.Clean coolant pump housing and mating faces.
8.Lubricate new sealing rings with Loctite 405 and
fit to coolant pump.
9.Fit coolant pump to housing.
10.Position housing cover, fit 5 bolts. Tighten to
25Nm
11.Connect hose to housing cover and tighten clip.
12.Refill cooling system.

26COOLING SYSTEM
2
REPAIR RADIATOR
Service repair no - 26.40.01
Remove
1.Disconnect battery negative lead.
WARNING: Do not carry out the next
instruction until the coolant is cool to
avoid personal injury from scalding.
2.Slacken clip and release bottom hose from
radiator, allow coolant to drain into a suitable
container
3.Slacken clip and release bottom hose from
radiator rail.
4.Slacken clip and release top hose from radiator.
5.Release air cleaner to throttle housing hose from
securing brackets.
6.Slacken clip and release bypass hose from
radiator.
7.Slacken clip and release top expansion hose
from radiator.
8.Remove 2 bolts securing radiator side support
brackets.
9.Collect L.H. support bracket and position R.H.
support bracket aside.
10.Slacken clip and release heater hose from
radiator rail.
11.Disconnect 2 multiplugs from cooling fan
assemblies.

Mpi
3
REPAIR
12.With assistance lift out radiator assembly.
Do not carry out further dismantling if component
is removed for access only.
13.Remove 2 bolts securing radiator rail to radiator.
14.Remove radiator rail.
15.Remove 8 nuts securing fan assemblies to
radiator.
NOTE: Vehicles without air conditioning
have one cooling fan fitted.
Refit
16.Position fan assemblies to radiator and tighten
nuts to
6Nm
17.Position radiator rail to radiator and secure with
bolts.
18.Position radiator to vehicle.
19.Secure radiator to body with the side support
brackets and retaining bolts.
20.Connect multiplugs to cooling fans.
21.Fit and secure 6 hoses to radiator.
22.Secure air cleaner to throttle housing to
brackets.
23.Refill cooling system.
24.Reconnect battery negative lead.

26COOLING SYSTEM
4
REPAIR THERMOSTATIC SENSOR
Service repair no - 19.22.18
Remove
1.Disconnect Lucar connector from sensor.
2.Remove sensor.
Refit
3.Clean sensor.
4.Apply Loctite 405 to threads of sensor.
5.Fit sensor and tighten to
15Nm
6.Connect Lucar to sensor.
7.Top-up cooling system.THERMOSTAT
Service repair no - 26.45.01
Remove
1.Position suitable container to collect coolant.
2.Slacken 2 clips and release radiator top hose.
3.Release bypass hose from securing bracket.
4.Release top hose from securing bracket.
5.Remove top hose.

Mpi
5
REPAIR 6.Remove clip securing thermostat in hose.
7.Lubricate hose in front of thermostat and
manoeuvre thermostat from hose.
Refit
8.Lubricate inside of top hose with liquid soap.
9.Manoeuvre thermostat into hose to previous
position.
10.Fit and tighten clip securing thermostat to top
hose.
11.Refit radiator hose.
12.Top-up cooling system.

ZF
5
REPAIR Remove
1.Select low range with transfer gear lever.
2.Remove knob and gaiter from transfer gear
lever.
3.Disconnect battery terminals.
4.Remove insulation pad from rocker cover and
inlet manifold.
5.On LH drive vehicles only, disconnect multi-plug
from top of brake fluid reservoir.
6.Release electrical harness from clips along top
of bulkhead and pull over to one side.7.Remove bolt securing transfer and main gearbox
breather pipe clip to rear of cylinder head.
8.Disconnect kick down cable at fuel injection
pump.
9.Drain coolant from cooling system.
10.Disconnect top hose from radiator.
11.Disconnect turbo charger hose from inter-cooler.
12.Remove starter heat shield.

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids