Engine Cooling - v8 4.4l Petrol Land Rover Range Rover Sport I

SPECIFICATIONS

FLUIDS

CAPACITY

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

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GENERAL

The cooling system employed is of the pressure relief by-pass type, which allows coolant to circulate around the engine and the heater circuit while the thermostat main valve is closed. The primary function of the cooling system is to maintain the engine within an optimum temperature range under changing ambient and engine operating conditions. Secondary functions are to provide heating for the passenger compartment and cooling for the transmission fluid and engine oil.

The cooling system comprises

1. A radiator
2. A passenger compartment heater matrix
3. A coolant pump
4. A thermostat
5. An expansion tank
6. An electro-viscous fan
7. Connecting hoses and pipes.

ENGINE COOLING SYSTEM

The coolant is circulated by a centrifugal pump mounted on the front of the engine and driven by an ancillary drive 'polyvee' belt. The coolant pump circulates coolant through the cylinder block and cylinder heads via a chamber located in the 'vee' of the engine. Having passed through the engine the coolant returns to the thermostat housing. The coolant then progresses down the 'top hose' to the heater pipe. The heater pipes lead to the bulkhead and return to the engine side of the thermostat.

The engine contains a normal thermostat, which is positioned such that the wax's temperature is controlled by both the coolant from the radiator and the bypass. This results in the thermostat being able to vary its opening temperature dependant on ambient conditions. The thermostat housing also contains a sprung loaded valve, which limits the amount of coolant using the bypass. This means the engine can run without coolant flowing through the bypass temporarily, to improve heater performance.

The radiator is a cross flow type with an aluminium matrix and has a drain tap on the lower right-hand rear face. The lower radiator mountings are located part way up the end tanks. The mountings are fitted with rubber bushes, which sit on the upper chassis rails. The radiator upper is mounted by pins, which are pushed through rubber bushes mounted in the Front End Carrier (FEC) above the radiator. The radiator also incorporates two connections for the transmission oil pipes.

The top and bottom hoses are mounted to the inlet and outlet sides of the thermostat housing.

The expansion tank is fitted forward of the LH suspension turret in the engine compartment. The expansion tank allows for the expansion of the coolant as the engine gets hot. It also supplies the engine with coolant as the coolant in the engine contracts. The tank also allows any air trapped in the coolant to be removed.

The liquid cooled transmission fluid cooler is mounted in the cold side radiator end tank. It is positioned in the middle of the LH end tank.

The engine oil cooler (EOC) is fed coolant from the bottom hose. Coolant is diverted from between the radiator and the thermostat, directed to the cooler and then returned to the bottom hose.

For additional airflow through the radiator matrix, particularly when the vehicle is stationary, there is an engine driven electro-viscous unit. This unit functions as a normal viscous fan, but with electronic control over the level engagement of the clutch. The Engine Control Module (ECM), which determines the required fan speed, controls the level of clutch engagement. The ECM determines engagement based on the coolant, ambient and transmission oil temperatures and air conditioning (A/C) system pressure. The fan is mounted using a left hand thread.

The viscous fan unit is electronically controlled by the ECM to optimise fan speed for all operating conditions.

Note. If the electrical connections to the viscous fan are disconnected the fan will 'idle' and overheating may result. The ECM stores the appropriate fault codes in this case.

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When the engine is running the coolant pump is driven by the ancillary drive belt. This forces coolant to circulate around the engine and heater, while the thermostat and bypass valve are shut. As the temperature and pressure increases the bypass valve is forced open allowing coolant to circulate through the bypass valve. When the temperature reaches 82°C (180°F) the main thermostat begins to open allowing coolant to circulate through the main radiator. As the thermostat progressively opens (fully open at 95°C (203°F)), the bypass valve progressively closes forcing any coolant through the heater or radiator. Once coolant is allowed to circulate through the radiator, the transmission fluid and the engine oil coolers begin to receive coolant flow.

The increased coolant volume, created by heat expansion, is directed to the expansion tank through a bleed hose from the top of the radiator. The expansion tank has an outlet hose, which is connected into the coolant circuit. This outlet hose returns the coolant to the system when the engine cools.

Coolant flows through the radiator from the top right hand tank to the bottom left hand tank and is cooled by air passing through the matrix. The temperature of the cooling system is monitored by the ECM via the Engine Coolant temperature (ECT) sensor located in the cylinder head. The ECM uses signals from this sensor to control the cooling fan operation and adjust fuelling according to engine temperature.

For additional information, refer to: Electronic Engine Controls .

To control the cooling fan, the ECM sends a Pulse Width Modulated (PWM) signal to the cooling fan module (integral to the ECM). The frequency of the PWM signal is used by the cooling fan module to determine the output voltage supplied to the fan motor.

The ECM varies the duty cycle of the PWM signal between 0 and 100% to vary the fan speed. If the PWM signal is outside the 0 to 100% range, the cooling fan module interprets the signal as an open or short circuit and runs the fans at maximum speed to ensure the engine and gearbox do not overheat.

The ECM operates the fan in response to inputs from the ECT sensor, the transmission oil temperature sensor, the A/C switch and the Air Conditioning (A/C) pressure sensor.

For additional information, refer to: AIR CONDITIONING .

The speed of the cooling fan is also influenced by vehicle road speed. The ECM adjusts the speed of the cooling fans, to compensate for the ram effect of vehicle speed, using the Controller Area Network (CAN) road speed signal received from the Anti-lock Braking System (ABS) module.

INSPECTION AND VERIFICATION

1. Verify the customer concern.
2. Visually inspect for obvious mechanical or electrical faults. VISUAL INSPECTION Mechanical Electrical Coolant leaks Coolant Hoses Coolant expansion tank Radiator Heater core Accessory drive belt Viscous fan Fuses Wiring harness Loose or corroded connector(s) Engine coolant temperature (ECT) sensor
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. Use the approved diagnostic system or a scan tool to retrieve any diagnostic trouble codes (DTCs) before moving onto the symptom chart or DTC index. Make sure that all DTCs are cleared following rectification

SYMPTOM CHART

DTC INDEX

Note. Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the scan tool to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read by the manufacturer-approved diagnostic system).

COOLING SYSTEM DRAINING, FILLING AND BLEEDING

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1. Position the vehicle on a lift.
2. Set the heater controls to maximum.
3. Disconnect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
4. Remove the engine cover. For additional information, refer to: «ENGINE COVER V8 4.4L PETROL»(/land-rover/range-rover-sport/i-2005-2009/remont/exteriorinterior-trim/#interior-trim-and-omamentation) .
5. Remove the coolant expansion tank cap.
6. Remove the front LH splash shield. Remove the 4 clips.
7. Remove the radiator access panel. Remove the 4 bolts.
8. Position a container to collect the fluid.
9. Release the clip and disconnect the radiator lower hose, allow the coolant to drain.
10. Remove the spare wheel and tire. Remove the tool kit. Access the winch.
11. Position a container to collect the fluid.
12. Disconnect the rear heater coolant hoses. Release the 2 clips. Allow the coolant to drain.
13. Connect the rear heater coolant hoses. Secure the clips.
14. Install the spare wheel and tire. Stow the tool kit.
15. Connect and secure the radiator lower hose. Secure with the clip.
16. Connect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
17. Connect exhaust extraction hoses to the tail pipes.
18. Loosen the coolant hose bleed screw.
19. Loosen the coolant expansion tank bleed screw.
20. Fill the cooling system to the upper level mark of the expansion tank.
21. Start and run the engine. Hold the engine speed at 2, 500 RPM for 30 seconds. Return the engine to idle for 30 seconds. Repeat the above procedure a further four times.
22. When a steady stream of coolant is running from the bleed point, close the coolant hose bleed screw.
23. Fill the cooling system, keeping coolant to the upper level mark of the expansion tank until a steady stream of coolant is seen returning to the expansion tank. Tighten the expansion tank bleed screw.
24. Install the coolant expansion tank cap.
25. Run the engine until the thermostat opens.
26. Switch the engine off and allow to cool.
27. Install the engine cover. For additional information, refer to: «ENGINE COVER V8 4.4L PETROL»(/land-rover/range-rover-sport/i-2005-2009/remont/exteriorinterior-trim/#interior-trim-and-omamentation) .
28. Clean any spilt coolant from the vehicle.
29. Install the radiator access panel. Tighten the 4 bolts to 10 Nm (7 lb.ft).
30. Install the front LH splash shield.
31. Check and top-up the coolant if required.

COOLING SYSTEM PRESSURE TEST

Note. The following procedure will enable the cooling system to be pressure tested for condition and leaks. Stage 1 will check the expansion tank cap register seal and the cap for leaks. Stage 2 will check the entire cooling system.

Note. It will be necessary to use the cooling system test kit, Part Number LR-218, which is available under the equipment programme.

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1. Examine the coolant hoses for signs of cracking, distortion and security of the hose connections.
2. Disconnect the coolant expansion tank bleed hose. Release the clip.
3. Install the 'T' piece adaptor (part of the cooling system test kit) between the coolant expansion tank and the coolant bleed hose. Secure with the 2 clips.
4. Install the coolant pressure pump assembly. Connect to the 'T' piece.
5. Pressurize the cooling system. Slowly pressurize the cooling system to 1.0 bar (100 kPa) (14.5 psi). Check the pressure remains above 0.9 bar (90 kPa) (13 psi) after waiting for 30 seconds. During the pressure drop check, listen for a hissing noise from the expansion tank cap.
6. Depressurize the cooling system. Disconnect the 'T' piece. Connect the coolant expansion tank bleed hose. Secure the clip.
7. Remove the coolant expansion tank cap.
8. Install adaptor K83 to the coolant expansion tank. Clean the component mating faces. Lubricate the seal.
9. Install the coolant pressure pump assembly. Slowly pressurize the cooling system to 1.5 bar (150kPa) (22 psi), check the pressure over a 5 minute period. A small pressure decay of approximately 0.15 bar (15 »kPa) (1 psi) over the first minute is normal, as the air in the expansion tank cools. If the pressure continues to drop after the initial tolerance, there is a coolant leak.
10. Depressurize and remove the pressure pump and gauge. Install the coolant expansion tank cap.

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1. Remove the LH headlamp assembly. For additional information, refer to: «HEADLAMP ASSEMBLY»(/land-rover/range-rover-sport/i-2005-2009/remont/exterior-lights/#exterior-lighting__headlamp-assembly) .
2. Release the windshield washer reservoir filler neck.
3. Release the coolant expansion tank. Remove the 2 bolts.
4. Release the power steering fluid reservoir.
5. Disconnect the 2 hoses from the coolant expansion tank. Position an absorbent cloth to collect fluid spillage. Position a container to collect the fluid. Clamp the hoses Release the 2 clips.
6. Remove the coolant expansion tank. Disconnect the coolant low level sensor electrical connector.
7. Remove the coolant low level sensor. Remove the coolant expansion tank support bracket.

INSTALLATION

1. Install the bracket.
2. Install the coolant low level sensor.
3. Install the coolant expansion tank. Connect the coolant low level sensor electrical connector.
4. Connect the coolant hoses to the expansion tank. Secure with the clips.
5. Top-up the coolant. Loosen the coolant expansion tank bleed screw. Fill the coolant expansion tank until coolant emerges from the cooling system air bleed screw. Remove the hose clamps. Tighten the bleed screw to 8 Nm (6 lb.ft).
6. Secure the coolant expansion tank. Tighten the bolts to 10 Nm (7 lb.ft).
7. Check and top-up the coolant. Install the coolant expansion tank pressure cap.
8. Secure the power steering fluid reservoir. Attach to the mounting bracket.
9. Secure the windshield washer reservoir filler neck. Locate in clip.
10. Install the LH headlamp assembly. For additional information, refer to: «HEADLAMP ASSEMBLY»(/land-rover/range-rover-sport/i-2005-2009/remont/exterior-lights/#exterior-lighting__headlamp-assembly) .

COOLING FAN

SPECIAL TOOL(S) Viscous coupling spanner 303-1142 Viscous coupling pulley retaining tool 303-1143

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1. Disconnect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
2. Remove the cooling fan shroud. For additional information, refer to: «COOLING FAN SHROUD»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol) .
3. Disconnect the cooling fan control electrical connector.
4. Using the special tools, remove the cooling fan. Remove the cooling fan assembly.
5. Remove the viscous coupling from the cooling fan. Remove the 4 bolts.

1. To install, reverse the removal procedure. Install the cooling fan to the viscous coupling, tighten the bolts to 10 Nm (7 lb.ft). Tighten the cooling fan assembly to 65 Nm (48 lb.ft).

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1. Disconnect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
2. Remove the air intake resonator. For additional information, refer to: «RESONATOR»(/land-rover/range-rover-sport/i-2005-2009/remont/mechanical/#intake-air-distribution-and-filtering-v8-44l-petrol) .
3. Remove the upper fan shroud. Release the coolant expansion hose from the clips. Release the fan wiring harness clip. Release the 3 fan shroud clips.

1. To install, reverse the removal procedure.

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1. Release the power steering fluid reservoir from the bracket.
2. Release the windshield washer reservoir filler neck.
3. Reposition the coolant expansion tank. Remove the 2 bolts.
4. Remove the engine coolant level switch. Disconnect the engine coolant level switch electrical connector.

1. Install the engine coolant level switch. Connect the engine coolant level switch electrical connector.
2. Secure the coolant expansion tank. Tighten the bolts to 10 Nm (7 lb.ft).
3. Secure the windshield washer reservoir filler neck.
4. Secure the power steering fluid reservoir to the bracket.

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1. Raise and support the vehicle.
2. Disconnect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
3. Drain the cooling system. For additional information, refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol__cooling-system-draining-filling-and-bleeding) .
4. Remove the viscous fan assembly. For additional information, refer to: «COOLING FAN»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol__cooling-fan) .
5. Remove the radiator grille. For additional information, refer to: «RADIATOR GRILLE»(/land-rover/range-rover-sport/i-2005-2009/remont/exteriorinterior-trim/#exterior-trim-and-omamentation) .
6. Remove the lower fan shroud. Release 2 clips from the cooling fan lower shroud. Release and remove the cooling fan lower shroud from the cooling pack.
7. Disconnect the coolant expansion tank hose. Release the clip.
8. Disconnect the radiator upper hose. Release the clip.
9. Disconnect the transmission cooler hoses. Release the 2 clips. Position a container to collect the fluid.
10. Remove the radiator securing pegs. Depress the 2 clips.
11. Remove the radiator upper deflector. Release the 2 clips.
12. Release the power steering fluid cooler. Release the clips. Tie the line aside.
13. Release the front differential breather line.
14. Remove the power steering fluid cooler line clip.
15. Remove the A/C manifold bolt.
16. Release the A/C condenser. Remove the 2 bolts. Release from the 2 clips.
17. Remove the radiator. Protect the elements from damage. With assistance, remove the radiator. Remove the 2 radiator retaining bolts.

1. Install the radiator. Remove the element protection. With assistance install the radiator. Align the radiator. Install the radiator retaining bolts. Tighten the bolts to 25 Nm (18 lb.ft).
2. Install the A/C condenser. Secure in the clips. Tighten the bolts to 6 Nm (4 lb.ft).
3. Install the A/C manifold bolt. Tighten the bolt to 10 Nm (7 lb.ft).
4. Install the power steering fluid cooler line clip.
5. Install the radiator upper deflector.
6. Install the power steering fluid cooler. Secure in the 3 clips.
7. Install the radiator securing pegs.
8. Install the transmission cooler hoses. Install the clips.
9. Install the radiator upper hose. Install the clip.
10. Install the radiator lower hose. Install the clip.
11. Install the coolant expansion tank hose to the upper radiator. Install the expansion tank hose clip.
12. Install the lower fan shroud. Install the cooling fan lower shroud. Install the 2 clips to the lower fan shroud.
13. Install the radiator grille. For additional information, refer to: «RADIATOR GRILLE»(/land-rover/range-rover-sport/i-2005-2009/remont/exteriorinterior-trim/#exterior-trim-and-omamentation) .
14. Install the viscous fan assembly. For additional information, refer to: «COOLING FAN»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol__cooling-fan) .
15. Refill the cooling system. For additional information, refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol__cooling-system-draining-filling-and-bleeding) .
16. Connect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
17. Check automatic transmission fluid level.

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1. Disconnect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
2. Remove the thermostat housing. Position a container to collect the fluid. Disconnect the coolant hoses from the thermostat housing. Remove the 3 bolts. Remove and discard the seal.
3. Remove the thermostat. Position the thermostat housing in a vice. Release and remove the thermostat.

1. Clean the thermostat cover and housing mating faces.
2. To install, reverse the removal procedure. Install a new thermostat seal. Tighten the bolts to 10 Nm (7 lb.ft).
3. Top up and bleed the coolant.
4. If required, carry out a long drive cycle. For additional information, refer to: «Powertrain Control Module (PCM) Long Drive Cycle Self-Test»(/land-rover/range-rover-sport/i-2005-2009/remont/engine-control-systems/#electronic-engine-controls-v8-44l-petrol__powertrain-control-module-pcm-long-drive) .

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1. Disconnect the battery ground cable. For additional information, refer to: «SPECIFICATIONS»(/land-rover/range-rover-sport/i-2005-2009/remont/charging-system/#battery-mounting-and-cables__specifications) .
2. Raise and support the vehicle.
3. Drain the cooling system. For additional information, refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol__cooling-system-draining-filling-and-bleeding) .
4. Remove the accessory drive belt. For additional information, refer to: «Accessory Drive Belt»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#accessory-drive-v8-44l-petrol) .
5. Remove the coolant pump drive pulley. Remove the 3 bolts.
6. Remove the coolant pump. Remove the 5 bolts. Discard the gasket.

1. To install, reverse the removal procedure. Clean the component mating faces.
2. Tighten the coolant pump retaining bolts. Tighten the 5 bolts to 10 Nm (7 lb.ft).
3. Tighten the coolant pump pulley retaining bolts. Tighten the bolts to 10 Nm (7 lb.ft).
4. Install the accessory drive belt. For additional information, refer to: «Accessory Drive Belt»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#accessory-drive-v8-44l-petrol) .
5. Refill the cooling system. For additional information, refer to: «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/land-rover/range-rover-sport/i-2005-2009/remont/cooling-system-mechanical/#engine-cooling-v8-44l-petrol__cooling-system-draining-filling-and-bleeding) .

See also:
• Electronic Engine Controls
• AIR CONDITIONING
• SPECIFICATIONS
• ENGINE COVER V8 4.4L PETROL
• HEADLAMP ASSEMBLY
• RESONATOR
• RADIATOR GRILLE
• Powertrain Control Module (PCM) Long Drive Cycle Self-Test
• Accessory Drive Belt
• visual inspection
• COOLING SYSTEM PRESSURE TEST
• COOLING SYSTEM DRAINING, FILLING AND BLEEDING
• COOLING FAN