Cooling System Land Rover Range Rover L322

COOLING SYSTEM SPECIFICATIONS

COMPONENT LOCATIONS

For component locations and cooling system flow (Scheme 1), (Scheme 2) and (Scheme 3).

Scheme 1

Scheme 2

Scheme 3

GENERAL

The cooling system employed is the bypass type, which allows coolant to circulate around the engine and the heater circuit while the thermostat 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. The cooling system comprises

1. Radiator
2. Passenger Compartment Heater Matrix
3. Transmission Fluid Cooler
4. Coolant Pump
5. Thermostat
6. Expansion Tank
7. Viscous Cooling Fan
8. Electric Cooling Fan
9. Connecting Hoses And Pipes
10. Fuel Burning Heater (FBH) - Selected Markets Only
11. Liquid Cooled Alternator Housing.

The coolant is circulated by a centrifugal type 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 the cylinder heads via a chamber located in the VEE of the engine. Having passed through the engine, the coolant returns via a rear-mounted manifold that features the connections for the heater matrix and through pipes running in the VEE of the engine to the coolant pump. The coolant pump also circulates coolant to the radiator-mounted transmission fluid cooler and the liquid cooled alternator housing via flexible hoses.

The die-cast coolant pump, driven by an ancillary drive belt, is fitted to the timing case cover. It contains the dual coolant temperature sensor and the electrically heated MAP CONTROLLED thermostat controlled by the engine management system.

The die-cast coolant pump, driven by an ancillary drive belt, is fitted to the timing case cover. It contains the dual coolant temperature sensor and the electrically heated MAP CONTROLLED thermostat controlled by the engine management system.

The map controlled thermostat incorporates a heating element inside a conventional expanding wax thermostat core which enables the engine management system to POWER the thermostat open when the engine is under full load and/or high output conditions. This provides sufficient cooling reserve through anticipation of the thermal load while allowing the engine to run at higher operating temperatures under part load conditions.

The radiator is a cross flow type with an aluminum matrix and has a drain tap on the lower left hand rear face. The bottom of the radiator is located in rubber bushes supported by plastic brackets which are clipped into the body longitudinals. The top of the radiator is located in rubber bushes secured by brackets fitted to the bonnet locking platform.

The radiator top and bottom hoses are connected to the outlet and inlet sides of the coolant pump housing respectively.

An expansion tank is fitted forward of the LH suspension turret in the engine compartment. The expansion tank allows for expansion of the coolant when the engine is hot and replaces the coolant into the system as the engine cools down.

The liquid cooled transmission fluid cooler is mounted on the plastic radiator support adjacent to the lower right hand rear of the matrix and receives coolant from either the bottom of the radiator or the return elbow pipe between the coolant pump and the radiator as required.

The Fuel Burning Heater (FBH) is located below the battery. The unit is connected in series with the coolant supply to the heater matrix.

For additional airflow through the radiator matrix, particularly when the vehicle is stationary, two cooling fans are fitted; one being driven by the engine via the coolant pump drive shaft and one being driven by an integral electric motor.

The engine driven fan contains a viscous coupling that allows the fan to slip as the engine speed increases. The fan is attached to a threaded spigot on the pulley with a left hand threaded nut. The fan draws air through the radiator to assist in cooling when the vehicle is stationary.

An electric fan controlled by the engine management system is fitted in front of the radiator assembly.

OPERATION

With the engine running, the coolant pump pulley is driven by an ancillary drive belt. When the engine is cold, the thermostat is closed and coolant is prevented from circulating through the radiator. Coolant is able to circulate through the engine and the passenger compartment heater matrix via a thermostat bypass.

As the temperature increases the thermostat begins to open, allowing cool fluid to be drawn from the radiator bottom hose through the pump and into the cylinder block and hot coolant to flow from the coolant pump housing to the radiator via the radiator top hose, where it is cooled by air passing through the matrix. When the thermostat opens fully, the full flow of coolant passes through the radiator.

Coolant is also drawn through the liquid cooled transmission fluid cooler and the liquid cooled alternator housing by the coolant pump via the coolant circuit.

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.

CHECK & TOP-UP

1. Check coolant level, top-up to MAX mark if necessary. With engine cold, remove expansion tank filler cap. CAUTION: Ensure that coolant level is not above base of float when float is at its highest position.
2. Top-up with recommended mixture of coolant and anti-freeze until float is at its highest position in the filler neck. (Scheme 4)
3. Check anti-freeze concentration. Check "O" rings on filler cap for condition, replace if necessary. Install expansion tank filler cap.

Scheme 4

Drain

1. Position vehicle on lift. Set heater controls to maximum. Disconnect battery ground lead. See «DISCONNECTING & RECONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/wheel-alignment/#specifications-procedures__disconnecting-reconnecting-battery).
2. Remove coolant expansion tank cap. Remove undertray. See «UNDERTRAY»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) under REMOVAL & INSTALLATION.
3. Position container beneath radiator to collect coolant. Install tube to drain tap, open tap and allow coolant to drain. (Scheme 5) Position container beneath engine to collect coolant. Remove cylinder block drain plug and allow coolant to drain. (Scheme 6) Discard sealing washer. Remove container.

Scheme 5

Scheme 6

Refill

1. Close radiator drain tap and remove tube. Using a NEW sealing washer, fit cylinder block drain plug and tighten to specification. Connect battery ground lead.
2. Remove bleed screw from expansion tank. (Scheme 7) Fill cooling system, keeping coolant to neck of expansion tank until a steady stream of coolant is emitted from bleed screw hole. Install and tighten bleed screw.
3. Install coolant expansion tank cap. Run engine until normal operating temperature is reached. Turn engine off and allow to cool. Check for leaks and fill expansion tank to MAX mark. (Scheme 4)
4. Clean coolant from body and surrounding area. Install undertray. See «UNDERTRAY»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) under REMOVAL & INSTALLATION.

Scheme 7

COUPLING UNIT - VISCOUS FAN

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

Removal

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove undertray. See «UNDERTRAY»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
4. Release 3 coolant hoses from clips on fan cowl. Remove screw securing fan cowl to radiator. (Scheme 8)
5. Disconnect harness multiplug and release cooling fan multiplug from mounting. (Scheme 9)
6. Use LRT-12-214 and LRT-12-215 to loosen viscous coupling lock nut and remove fan assembly from coolant pump. (Scheme 10) NOTE: Thread is left handed.
7. Remove scrivets securing fan cowl. (Scheme 11)
8. Release cowl from mountings and remove cowl and fan assembly. (Scheme 12)
9. Place viscous coupling and fan to work bench.
10. Remove 4 bolts and remove coupling from fan. (Scheme 13)

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Installation

1. Clean coupling and fan mating faces.
2. Fit viscous coupling to fan and tighten 4 bolts to 10 Nm (7 ft. lbs).
3. Carefully fit fan and cowl assembly, secure the cowl to mountings.
4. Fit fan assembly to coolant pump. Using LRT-12-214 and LRT-12-215 tighten viscous coupling lock nut to 45 Nm (33 ft. lbs).
5. Fit cooling fan harness and multiplug to fan cowl.
6. Fit screw securing fan cowl to radiator.
7. Secure 3 coolant hoses to clips on fan cowl.
8. Fit undertray. See «UNDERTRAY»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .
9. Connect battery earth lead.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Drain coolant. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
4. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(/land-rover/range-rover/l322-2002-2005/remont/heater/#heating-and-ventilation-removal-installation).
5. Remove throttle body. See «THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
6. Remove bolt securing engine harness to coolant manifold. (Scheme 14)
7. Disconnect heater pipes from coolant manifold.
8. Release harness from 2 clips on coolant manifold.
9. Remove bolt securing multiplug to bell housing. (Scheme 15)
10. Release transfer gearbox breather pipe from clip.
11. Remove 6 bolts securing coolant manifold to cylinder heads. (Scheme 16)
12. Secure coolant pipes and remove coolant manifold. (Scheme 17)
13. Remove harness retaining clips.
14. Discard "O" rings and gaskets.

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Clean coolant manifold and cylinder head mating faces.
2. Fit new "O" rings to coolant manifold.
3. Fit harness retaining clips.
4. Position new gaskets and coolant manifold to cylinder heads, fit bolts and tighten to 10 Nm (7 ft. lbs).
5. Fit transfer gearbox breather pipe to clip.
6. Fit bolt securing multiplug to bell housing and tighten to 25 Nm (18 ft. lbs).
7. Fit harness into clips.
8. Connect heater pipes to coolant manifold.
9. Fit bolt securing engine harness to coolant manifold and tighten to 10 Nm (7 ft. lbs).
10. Fit throttle body. See «THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
11. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(/land-rover/range-rover/l322-2002-2005/remont/heater/#heating-and-ventilation-removal-installation) .
12. Connect battery earth lead.
13. Refill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .

1. Drain coolant. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
2. Remove inlet manifold. See «GASKET(S) - INLET MANIFOLD»(/land-rover/range-rover/l322-2002-2005/remont/exhaust/#manifold-exhaust-system).
3. Remove bolt securing engine harness to coolant manifold.
4. Release harness from 2 clips on coolant manifold.
5. Release transfer gearbox breather pipe from clip.
6. Remove 6 bolts securing coolant manifold to cylinder heads. (Scheme 18)
7. Secure coolant pipes and reposition coolant manifold.
8. Remove and discard coolant manifold gaskets.
9. Remove 2 coolant pipes from coolant pump. (Scheme 19)
10. Discard "O" rings.

Scheme 18

Scheme 19

1. Clean gasket mating faces.
2. Fit NEW "O" rings to coolant manifold.
3. Fit coolant pipes to the coolant pump.
4. Position new gaskets and coolant manifold to cylinder heads, fit bolts and tighten to 10 Nm (7 ft. lbs).
5. Fit transfer gearbox breather pipe to clip.
6. Fit harness into clips.
7. Fit bolt securing engine harness to coolant manifold and tighten to 10 Nm (7 ft. lbs).
8. Fit inlet manifold. See «GASKET(S) - INLET MANIFOLD»(/land-rover/range-rover/l322-2002-2005/remont/exhaust/#manifold-exhaust-system) .
9. Refill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove coolant pump to coolant manifold pipes. See «PIPE(S) - COOLANT PUMP TO COOLANT MANIFOLD»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
4. Remove 20 bolts securing coolant gallery sealing plate and remove the sealing plate. (Scheme 20)
5. Discard gasket from coolant gallery sealing plate and cylinder block.

Scheme 20

1. Clean coolant gallery sealing plate and cylinder block mating faces.
2. Fit new gasket to coolant gallery sealing plate.
3. Fit and secure coolant gallery sealing plate to cylinder block, tighten bolts to 10 Nm (7 ft. lbs).
4. Fit coolant pump to coolant manifold pipes. See «PIPE(S) - COOLANT PUMP TO COOLANT MANIFOLD»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .
5. Connect battery earth lead.

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Disconnect battery earth lead.
2. Position vehicle on lift.
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
4. Remove fan cowl. See «COUPLING UNIT - VISCOUS FAN»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system__coupling-unit-viscous-fan).
5. Remove screw and release gearbox cooler manifold from radiator. (Scheme 21)
6. Release hose clips and disconnect top hose, bottom hose and expansion tank hose from radiator. (Scheme 22)
7. Remove radiator assembly retaining bolts from bonnet locking platform. (Scheme 23)
8. Ease radiator assembly rearward, release and remove radiator retaining clips.
9. Carefully remove radiator.

Scheme 21

Scheme 22

Scheme 23

1. Position radiator to mounting, fit and secure retaining clips.
2. Position and secure radiator assembly to bonnet locking platform.
3. Position gearbox cooler to radiator and tighten securing screw.
4. Connect hoses to radiator and secure with clips.
5. Fit viscous coupling. See «COUPLING UNIT - VISCOUS FAN»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system__coupling-unit-viscous-fan) .
6. Connect battery earth lead.
7. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

Note. The thermostat heater is serviced with the thermostat and must not be removed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
4. Remove air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation).
5. Disconnect multiplug from thermostat heater. (Scheme 24)
6. Release clip and disconnect radiator bottom hose from thermostat housing.
7. Remove 4 bolts and remove thermostat housing from coolant pump. Discard seal. (Scheme 25)

Scheme 24

Scheme 25

1. Clean mating face of thermostat housing and coolant pump.
2. Fit new seal to thermostat housing.
3. Fit thermostat housing and tighten bolts to 10 Nm (7 ft. lbs).
4. Connect radiator bottom hose to thermostat housing and secure with clip.
5. Connect multiplug to thermostat heater.
6. Connect air intake hose. See «HOSE - AIR FLOW METER TO THROTTLE BODY»(/land-rover/range-rover/l322-2002-2005/remont/removal-installation/#engine-management-removal-installation) .
7. Connect battery earth lead.
8. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .

Note. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

1. Position vehicle on lift.
2. Disconnect battery earth lead.
3. Remove thermostat. See «THERMOSTAT»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system).
4. Remove viscous fan. See «COUPLING UNIT - VISCOUS FAN»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system__coupling-unit-viscous-fan).
5. Remove ancillary drive belt. See «ANCILLARY DRIVE BELT»(/land-rover/range-rover/l322-2002-2005/remont/charging-system/#generators-regulators).
6. Release clips and disconnect radiator top hose from coolant pump and alternator. (Scheme 26)
7. If fitted: Remove Allen bolt securing secondary air injection (SAI) pipe clip to coolant pump. (Scheme 27)
8. If fitted: Remove bolt securing SAI pipe to LH cylinder head. (Scheme 28)
9. If fitted: Remove bolt securing SAI pipe to RH cylinder head. (Scheme 29)
10. If fitted: Release SAI pipe from cylinder heads and position aside. Discard "O" rings.
11. Using LRT-12-215 to hold coolant pump pulley, loosen 4 bolts securing coolant pump pulley. (Scheme 30)
12. Remove 4 bolts securing coolant pump pulley and remove pulley.
13. Disconnect ECT sensor multiplug. (Scheme 31)
14. Remove 6 bolts securing coolant pump to cylinder block and remove coolant pump. (Scheme 32) NOTE: DO NOT allow the coolant pipes to be released from the coolant manifold during the removal of the coolant pump. If the coolant pipes are released from the coolant manifold the "O" rings must be replaced.
15. Remove and discard 2 "O" rings from coolant pump.
16. Clean gasket mating faces. NOTE: DO NOT carry out further dismantling if component is removed for access only.
17. Remove ECT sensor and discard sealing washer.

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Using new sealing washer, fit ECT sensor and tighten to 14 Nm (11 ft. lbs).
2. Lubricate NEW "O" rings and fit to sealing groves in coolant pump.
3. Fit a new gasket and coolant pump to engine. Tighten bolts to 10 Nm (7 ft. lbs).
4. Connect ECT sensor multiplug.
5. Ensure mating faces of coolant pump pulley and flange are clean. Fit pulley and finger tighten securing bolts.
6. Using LRT-12-215 to hold coolant pump pulley, tighten the bolts securing coolant pump pulley to 10 Nm (7 ft. lbs).
7. Lubricate NEW "O" rings and fit to SAI. Fit SAI pipe and tighten securing bolts to 10 Nm (7 ft. lbs).
8. Connect coolant hose to coolant pump and alternator.
9. Fit ancillary drive belt. See «ANCILLARY DRIVE BELT»(/land-rover/range-rover/l322-2002-2005/remont/charging-system/#generators-regulators) .
10. Fit thermostat. See «THERMOSTAT»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system) .
11. Fit viscous fan. See «COUPLING UNIT - VISCOUS FAN»(/land-rover/range-rover/l322-2002-2005/remont/cooling-system-mechanical/#cooling-system__coupling-unit-viscous-fan) .
12. Connect battery earth lead.

Removal & Installation

1. Raise and support vehicle. Release clips and remove towing eye finisher. (Scheme 33) Remove 6 screws securing air dam to undertray. Remove 2 screws securing air dam support brackets to bumper. Carefully ease air dam aside for access and remove 4 screws.
2. Remove 2 screws securing left inner edge of wheel arch liner to undertray, repeat on right side. Remove 6 remaining screws securing undertray, release panel and remove. Further dismantling is not necessary if component is removed for access only. Remove 6 screw retaining clips from undertray. To install, reverse removal procedure.

Scheme 33

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• DISCONNECTING & RECONNECTING BATTERY
• 80.15.62 PLENUM -- AIR INTAKE
• THROTTLE BODY
• GASKET(S) - INLET MANIFOLD
• ANCILLARY DRIVE BELT
• UNDERTRAY
• COUPLING UNIT - VISCOUS FAN