2002 LAND ROVER DISCOVERY Oil cooler

STEERING
DESCRIPTION AND OPERATION 57-5
Description
General
The major steering components comprise an impact absorbing telescopic steering column, a Power Assisted Steering
(PAS) box, a PAS pump, and fluid reservoir. Hydraulic fluid from the fluid reservoir is filtered and then supplied
through the suction line to the inlet on the PAS pump. The PAS pump supplies fluid to the steering box through a
pressure line routed above the front cross member. Fluid returns to the reservoir along the same route through a
return line. On LH drive vehicles the pipe route above the front cross member is still used, the length of pipe acting
as an oil cooler.
To minimise driver's injury in the event of an accident the steering system has a number of safety features including
a collapsible steering column. An additional safety feature is an air bag located in the steering wheel.

+ RESTRAINT SYSTEMS, DESCRIPTION AND OPERATION, Description - SRS.
Steering column assembly and intermediate shaft
The steering column central shaft comprises of two shafts, the upper shaft is splined to accept the steering wheel and
located in bearings in the column tube. A universal joint is located on the bottom of the upper shaft, the joint allows
for angular movement between the upper and lower shafts. The lower shaft is made in two parts, the top section of
the lower shaft is located outside of the lower section. The two sections of the lower shaft are connected by two nylon
injection moulded shear pins. The lower shaft goes through a lower bearing attached to the bulkhead, the lower shaft
is connected by a universal joint to the intermediate shaft in the engine compartment.
Steering column
An upper column tube provides for the location of the steering lock and ignition switch and also the steering switch
gear and a rotary coupler. The rotary coupler provides the electrical connection for the steering wheel mounted airbag,
switches and horn. The upper mounting bracket has two slots, a slotted metal bracket is held in each slot by four resin
shear pins.
The column is mounted on four captive studs which are located on a column mounting bracket. The captive studs
pass through the metal brackets, locknuts secure the steering column to the bulkhead. The two lower mountings are
fixed and cannot move when loads are applied to them. The upper mounting is designed to disengage or deform when
a load is applied, allowing the column to collapse in the event of an accident. The steering column must be replaced
as a complete assembly if necessary.
When an axial load is applied to the upper column tube, energy absorption is achieved by the following mechanism:
lthe mounting bracket deforms,
lthe resin shear pins holding the slotted metal brackets shear,
lthe top mounting bracket slides out of the slotted metal brackets.
The slotted metal brackets remain on the captive studs on the bulkhead. If the column mounting moves, injection
moulded shear pins retaining the two sections of the lower column shaft will shear. This allows the two sections of the
lower shaft to 'telescope' together.
In the event of a collision where the steering box itself moves, two universal joints in the column allow the intermediate
shaft to articulate, minimising movement of the column towards the driver. If movement continues energy absorption
is achieved by the following mechanism:
lthe decouple joint in the intermediate shaft will disengage,
lthe lower section of the steering column shaft will move through the lower bearing,
lthe injection moulded shear pins retaining the two sections of the lower column shaft will shear.
This allows the two sections of the lower shaft to 'telescope' together reducing further column intrusion. Protection to
the drivers face and upper torso is provided by an SRS airbag module located in the centre of the steering wheel.

+ RESTRAINT SYSTEMS, DESCRIPTION AND OPERATION, Description - SRS.

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/in2) 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
ADJUSTMENTS 57-25
7.Syphon PAS fluid from reservoir.
8.Position container to collect PAS fluid spillage.
9.Clean steering box pipe pipe housing.
10.Remove bolt securing pipe clip to steering box.
Leaving the feed pipe from PAS reservoir in
place, release clip and PAS cooler pipe from
steering box. Discard lower 'O' ring.
11.Fit LRT-57-041 adaptor to steering box.
12.Fit PAS cooler pipe to LRT-57-041, align
retaining clip and tighten Allen bolt to 25 Nm (18
lbf.ft).
13.Hang pressure gauge in a safe position under
bonnet.
14.Remove PAS reservoir filler cap, fill to level
indicator and refit cap.
15.Connect battery earth lead.
16.Start engine and allow air to bleed from PAS
system by turning steering from lock to lock.
Stop engine and check PAS fluid level.
17.Ensure steering system and test equipment are
free from leaks.
18.Open test valve on LRT-57-001 and start
engine.
19.With the engine at idle, slowly turn the steering
wheel and hold on full lock.
20.Note the pressure reading on LRT-57-005.21.Repeat the pressure check for the opposite full
lock.
22.Test pressure should be between 21 and 62
bar, (300 to 900) psi. Dependant on road
surface.
23.With the engine at idle, centralise the steering
wheel. Pressure should read 7 bar (100 psi) or
below.
24.Pressure outside the above tolerance indicates
a fault.
25.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.
26.If gauge does not register between 75 and 103
bar, (1500 psi), (maximum pump pressure), the
pump is faulty.
27.If maximum pump pressure is correct suspect
the steering box.
28.On completion stop engine, disconnect battery
earth lead and syphon fluid from PAS reservoir.
29.Remove test equipment from LRT-57-002.
30.Remove bolt and clip from steering box.
31.Release PAS cooler pipe from LRT-57-041 and
discard 'O' ring. Leaving PAS reservoir oil feed
pipe in place, release LRT-57-041 from
steering box and discard 'O' ring.
32.Fit new 'O' rings to PAS cooler pipe.
33.Fit PAS cooler pipe to steering box, align
retaining clip, fit bolt and tighten to 25 Nm (18
lbf.ft).
34.Remove PAS reservoir filler cap, fill to level
indicator and refit cap.
35.Clean chassis member.
36.Fit splash shield and secure with screws.
37.Connect battery earth lead.
38.Start engine.
39.Start engine and allow air to bleed from PAS
system, by turning steering from lock to lock.
40.Visually check PAS system for leaks.
41.Check power steering fluid, if aerated, wait until
fluid is free from bubbles then top-up reservoir
to 'UPPER' level mark.
42.Visually check PAS system for leaks.
43.Dismantle test equipment.

STEERING
57-44 REPAIRS
14.Position steering column assembly in a vice.
15.Remove 2 screws and remove ignition switch.
16.Remove cable tie and remove multiplug from
ignition switch.
17.Centre punch or drill out steering lock shear
bolts.
18.Remove steering lock
Refit
1.Position lock to steering column assembly and
fit shear bolts. Do not tighten shear bolts at this
stage.
2.Insert starter key, check operation of steering
lock and that key turns freely.
3.Tighten shear bolts fully and shear heads off.
4.Position ignition switch to column, fit and
tighten screws.
5.Position multiplug to switch and secure with
new cable tie.
6.Fit rubber boot to column.
7.Remove column from vice.
8.Position steering to fascia rail fit nuts and
tighten to 22 Nm (16 lbf.ft).
9.Secure harness to column clip.
10.Position rubber grommet.
11.Close access panel and secure turn buckles.
12.Connect ignition switch multiplugs.
13.Position column switch and tighten clamp
screw.
14.Connect column switch multiplugs.
15.Position passive coil, connect multiplug and
illumination bulb.
16.Fit steering column nacelle.

+ STEERING, REPAIRS, Nacelle -
steering column.
17.Fit rotary coupler.

+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
18.Close fascia lower access panel.
19.Fit steering column intermediate shaft.

+ STEERING, REPAIRS, Shaft -
intermediate and universal joint - steering
column.
Shaft - intermediate and universal joint -
steering column
$% 57.40.22
The intermediate shaft has a red indicator clip
fitted which must be inspected at service, and
after the vehicle has been subject to an impact.
If the clip is not present or is not fully seated
against the clamp plate, a new assembly must be
fitted.
Remove
1. LHD diesel: Loosen 2 clips securing
intercooler to turbocharger hose. Place hose
aside.

AIR CONDITIONING
82-6DESCRIPTION AND OPERATION
Condenser
1Condenser matrix
2Outlet connection
3Inlet connection
The condenser transfers heat from the refrigerant to the surrounding air.
The condenser is installed immediately in front of the oil coolers. Rubber mounting bushes are used to mount the
condenser to the chassis sidemembers and brackets on the headlamp panels.
Ambient air, passing through the condenser matrix due to ram effect and/or the cooling fan, absorbs heat from the
refrigerant, which changes state from a vapour to a liquid.