Engine Cooling (4.4l) Land Rover Range Rover L322

SPECIFICATIONS

FLUIDS

CAPACITY

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

* Note: Left-hand thread

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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. An Oil Cooler Mixer Valve (OCMV)
8. 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 conventional wax thermostat, which is positioned such that the wax's temperature is controlled by both the coolant from the radiator and the bypass. The thermostat housing also contains a sprung loaded valve, which limits the amount of coolant using the bypass. At low engine speeds most coolant is diverted through the heater. At higher engine speeds the bypass opens to protect the heater matrix from to higher pressures and flow rates. 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 plastic mounts clipped into the chassis rails. The radiator upper is mounted by pins, which are pushed through the bonnet locking platform above the radiator assembly. The top and bottom hoses are mounted to the inlet and outlet sides of the thermostat housing. The coolant degas tank is fitted behind the RH side headlight of the RH in the engine compartment. The tank allows any air trapped in the coolant to be removed. The liquid cooled Transmission Oil Cooler (TOC) is mounted to the fan cowl. It is fed coolant from the sub-cooled section of the radiator, which is controlled by the Oil Cooler Mixer Valve (OCMV). The liquid cooled Engine Oil Cooler (EOC) is fed coolant from the sub-cooled section of the radiator, which is controlled by the OCMV. It is integral with the oil filter housing. Both the TOC and the EOC are connected in parallel. The OCMV is a 2 stage valve, which controls the heating and cooling of the engine and transmission oils. The operation of the first stage is to warm up both oils from cold to improve emissions and driveability. The second stage is fully operational once the coolant temperature reaches 91° C and allows cooling of both oils (starts to open at 84°C). For additional airflow through the radiator matrix, particularly when the vehicle is stationary or slow moving, 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 viscous 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 LH thread (RH thread for supercharged derivatives).

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. A 'check engine light' will also be displayed in the instrument cluster.

ENGINE COOLING SYSTEM OPERATION

Cooling System Coolant Flow

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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 88°C (190°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. 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. A small flow of coolant from the top of the engine is directed to the degas tank where any 'trapped' air is separated. The degas tank also controls the cooling system running pressures. The temperature of the cooling system is monitored by the ECM via the Engine Coolant temperature (ECT) sensor located in the coolant housing. The ECM uses signals from this sensor to control the cooling fan operation. For additional information, refer to: Electronic Engine Controls - Description & Operation To control the cooling fan, the ECM sends a Pulse Width Modulated (PWM) signal to the cooling fan clutch. The frequency of the PWM signal is used by the cooling fan clutch to control the level of clutch engagement. The ECM varies the duty cycle of the PWM signal between 0 and 100% to vary the clutch engagement and thus fan speed. The ECM operates the fan in response to inputs from the ECT sensor, the transmission oil temperature sensor, the Air Conditioning (A/C) switch and the A/C pressure sensor. For additional information, refer to: Air Conditioning - Description & Operation 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.

COOLING SYSTEM DRAINING, FILLING AND BLEEDING

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1. Position the vehicle on a lift.
2. Set the heater controls to HOT.
3. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
4. Remove the engine cover. Refer to «Engine Cover - 4.4L»(/land-rover/range-rover/l322-2005-2009/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
5. Remove the coolant expansion tank cap.
6. Remove the engine undershield. Refer to «Radiator Splash Shield»(/land-rover/range-rover/l322-2005-2009/remont/exterior-body-panels/#front-end-body-panels) .
7. Drain the coolant. Position a container to collect the fluid. Attach a hose to the radiator drain tap. Open the tap.
8. Close the radiator drain tap and remove the hose. Remove the container.
9. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
10. Connect exhaust extraction hoses to the tail pipes.
11. Loosen the coolant hose bleed screw.
12. Loosen the coolant expansion tank bleed screw.
13. Fill the cooling system expansion tank. When coolant runs from the engine bleed point bubble-free, tighten the bleed screw. When coolant runs from the expansion tank bleed point bubble-free, tighten the bleed screw. Install the coolant expansion tank cap.
14. Clamp the coolant bleed hose as shown.
15. Start and run the engine. Make sure the heater motor is switched off. Hold the engine speed at 2000 rpm, until bubble-free coolant, can be seen returning to the expansion tank via the bleed hose. Set the heater controls to HOT with the motor speed at minimum. Hold the engine speed at 2000 rpm until warm air is expelled from the heater.
16. Switch the engine off. Remove the clamp. Check and top-up the coolant.
17. Start and run the engine until the thermostat opens. Switch the engine off and allow to cool.
18. Check and top-up the coolant if required.
19. Disconnect the exhaust extraction hoses from the tail pipes.
20. Clean any spilt coolant from the vehicle.
21. Install the engine cover. Refer to «Engine Cover - 4.4L»(/land-rover/range-rover/l322-2005-2009/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
22. Install the engine undershield. Refer to «Radiator Splash Shield»(/land-rover/range-rover/l322-2005-2009/remont/exterior-body-panels/#front-end-body-panels) .

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 programmer.

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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.

REMOVAL

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
2. Remove the coolant expansion tank cap.
3. Disconnect the 2 hoses from the coolant expansion tank. Clamp the hoses Release the 2 clips.
4. Disconnect the coolant low level sensor electrical connector.
5. Remove the coolant expansion tank. Remove the 2 bolts. Release from the clip.

INSTALLATION

1. Install the coolant expansion tank. Secure with the clip. Tighten the bolts to 10 Nm (7 lb.ft).
2. Connect the coolant low level sensor electrical connector.
3. Connect the expansion tank coolant hoses. Secure with the clips. Remove the hose clamps.
4. Top-up the coolant. Fill with coolant to approximately 30mm ABOVE the maximum cold fill line.
5. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
6. Bleed the air from the cooling system. Make sure that the expansion tank cap is removed. Connect exhaust extraction hoses to the tail pipes. Start and run the engine. Hold the engine at 3000 rpm for 1 minute. Return the engine to idle for five minutes. Hold the engine at 3000 rpm for 1 minute. Make sure that the coolant level is maintained to approximately 30mm ABOVE maximum cold fill line during the bleed procedure (with the expansion tank cap removed).
7. Check all coolant hoses for visible signs of coolant leaks.
8. Install the expansion tank cap after making sure that the final coolant level is 30mm above the maximum cold fill line.

COOLING FAN

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Viscous coupling spanner 303-1142 Viscous coupling pulley retaining tool 303-1143

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
2. Raise and support the vehicle.
3. Recover the A/C refrigerant. Refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/land-rover/range-rover/l322-2005-2009/remont/ac-compressor/#climate-control-system-general-information) .
4. Remove the air intake resonator. Refer to «Intake Air Resonator»(/land-rover/range-rover/l322-2005-2009/remont/mechanical/#intake-air-distribution-and-filtering-44l) .
5. Remove the radiator splash shield. Refer to «Radiator Splash Shield»(/land-rover/range-rover/l322-2005-2009/remont/exterior-body-panels/#front-end-body-panels) .
6. Release the A/C line from the cooling fan shroud. Remove the Allen bolt. Release from the 3 clips. Remove and discard the O-ring seal.
7. If installed, release the pollution sensor.
8. Release the cooling fan wiring harness. Disconnect the electrical connector. Release the 2 clips.
9. Release the automatic transmission fluid cooler. Remove the Torx screw. Release from the 2 clips.
10. Release the 2 coolant hoses from the cooling fan shroud. Release from the 4 clips.
11. Remove the cooling fan shroud lower clip.
12. Remove the 2 cooling fan shroud upper clips.
13. Remove the 2 cooling fan shroud Torx screws.
14. Using the special tools, release the cooling fan.
15. Remove the cooling fan and shroud.
16. Remove the viscous coupling from the cooling fan. Remove the 4 bolts.

1. Attach the viscous coupling to the cooling fan. Tighten the bolts to 10 Nm (7 lb.ft).
2. Install the cooling fan and shroud. Tighten the cooling fan to 65 Nm (48 lb.ft). Install the clips. Tighten the Torx screws.
3. Secure the coolant hoses.
4. Attach the automatic transmission fluid cooler. Secure in the clips. Tighten the Torx screw.
5. Attach the cooling fan wiring harness. Secure the clips. Connect the electrical connector.
6. If installed, attach the pollution sensor.
7. Connect the A/C line. Install a new O-ring seal. Tighten the Allen bolt to 10 Nm (7 lb.ft).
8. Install the radiator splash shield. Refer to «Radiator Splash Shield»(/land-rover/range-rover/l322-2005-2009/remont/exterior-body-panels/#front-end-body-panels) .
9. Install the air intake resonator. Refer to «Intake Air Resonator»(/land-rover/range-rover/l322-2005-2009/remont/mechanical/#intake-air-distribution-and-filtering-44l) .
10. Recharge the A/C system. Refer to «Air Conditioning (A/C) System Recovery, Evacuation and Charging»(/land-rover/range-rover/l322-2005-2009/remont/ac-compressor/#climate-control-system-general-information) .
11. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
2. Raise and support the vehicle.
3. Remove the radiator grille. Refer to «Radiator Grille»(/land-rover/range-rover/l322-2005-2009/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) .
4. Drain the cooling system. See «Cooling System Draining, Filling and Bleeding»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-system-draining-filling-and-bleeding) .
5. Remove the cooling fan. See «Cooling Fan»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-fan) .
6. Release the coolant expansion tank. Remove the 2 bolts. Release from the clip. Tie the coolant expansion tank aside.
7. Disconnect the 2 upper coolant hoses from the radiator. Release the 2 clips.
8. Disconnect the 2 lower coolant hoses from the radiator. Release the 2 clips.
9. Release the power steering fluid reservoir. Remove the 3 bolts. Tie the reservoir aside.
10. Disconnect the refrigerant line from the A/C condenser. Remove the Allen bolt. Remove and discard the O-ring seal.
11. Release the power steering fluid cooler. Remove the clip.
12. Release the radiator assembly. Remove the 2 screws. Remove the 2 support brackets.
13. With assistance, remove the radiator assembly.
14. Remove the radiator.

1. Install the radiator.
2. With assistance, install the radiator assembly. Install the support brackets. Tighten the screws.
3. Secure the power steering fluid cooler. Install the clip.
4. Connect the A/C refrigerant line. Clean the components. Install a new O-ring seal. Tighten the Allen bolt to 10 Nm (7 lb.ft).
5. Attach the power steering fluid reservoir. Tighten the bolts to 10 Nm (7 lb.ft).
6. Connect the radiator coolant hoses. Secure with the clips.
7. Attach the coolant expansion tank. Secure with the clip. Tighten the bolts to 10 Nm (7 lb.ft).
8. Install the cooling fan. See «Cooling Fan»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-fan) .
9. Install the radiator grille. Refer to «Radiator Grille»(/land-rover/range-rover/l322-2005-2009/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) .
10. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
11. Refill and bleed the cooling system. See «Cooling System Draining, Filling and Bleeding»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-system-draining-filling-and-bleeding) .

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
2. Remove the air intake resonator. Refer to «Intake Air Resonator»(/land-rover/range-rover/l322-2005-2009/remont/mechanical/#intake-air-distribution-and-filtering-44l) .
3. Remove the thermostat housing. Position a container to collect the fluid. Release the clip. Disconnect the coolant hose. Remove the 3 bolts. Remove and discard the seal.
4. Remove the thermostat. Position the thermostat housing in a vice. Release and remove the thermostat.

1. Install the thermostat. Clean the component mating faces. Install the components.
2. Install the thermostat housing. Clean the component mating faces. Install a new thermostat seal. Tighten the bolts to 10 Nm (7 lb.ft). Connect the hose and secure with the clip.
3. Install the air intake resonator. Refer to «Intake Air Resonator»(/land-rover/range-rover/l322-2005-2009/remont/mechanical/#intake-air-distribution-and-filtering-44l) .
4. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
5. Top-up and bleed the coolant.

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
2. Raise and support the vehicle.
3. Drain the cooling system. See «Cooling System Draining, Filling and Bleeding»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-system-draining-filling-and-bleeding) .
4. Remove the cooling fan. See «Cooling Fan»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-fan) .
5. Remove the cooling fan drive belt. Using a 1/2 inch square drive bar, rotate the drive belt tensioner clockwise.
6. Remove the cooling fan drive pulley. Remove the 3 bolts.
7. Remove the cooling fan drive hub bearing. Remove the 5 bolts.
8. Remove the cooling fan belt tensioner. Remove the bolt.
9. Release the accessory drive belt. Rotate the accessory drive belt tensioner counter-clockwise, using a 3/8 " drive wrench.
10. Remove the accessory drive belt.
11. Remove the coolant pump drive pulley. Remove the 3 bolts.
12. Remove the coolant pump. Remove the 5 bolts. Discard the gasket.

1. Install the coolant pump. Clean the component mating faces. Tighten the 5 bolts to 10 Nm (7 lb.ft).
2. Install the coolant pump drive pulley. Tighten the 3 bolts to 10 Nm (7 lb.ft).
3. Install the accessory drive belt.
4. Install the cooling fan belt tensioner. Tighten the M10 bolt to 45 Nm (33 lb.ft).
5. Install the cooling fan drive hub bearing. Tighten the bolts to 10 Nm (7 lb.ft).
6. Install the cooling fan drive pulley. Tighten the bolts evenly to 25 Nm (18 lb.ft).
7. Install the cooling fan drive belt. Using a 1/2 inch square drive bar, rotate the drive belt tensioner clockwise.
8. Install the cooling fan. See «Cooling Fan»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-fan) .
9. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
10. Refill the cooling system. See «Cooling System Draining, Filling and Bleeding»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-system-draining-filling-and-bleeding) .

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1. Disconnect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
2. Raise and support the vehicle.
3. Drain the cooling system. See «Cooling System Draining, Filling and Bleeding»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-system-draining-filling-and-bleeding) .
4. Remove the cooling fan. See «Cooling Fan»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-fan) .
5. Remove the cooling fan drive belt. Using a 1/2 inch square drive bar, rotate the drive belt tensioner clockwise.
6. Remove the throttle body gasket. Refer to «Throttle Body Gasket»(/land-rover/range-rover/l322-2005-2009/remont/fuel-system/#fuel-charging-and-controls-44l) .
7. Position the throttle body aside for access. Disconnect the TP sensor electrical connector. Release the coolant manifold throttle body electrical harness clip.
8. Disconnect the coolant manifold to radiator hose. Remove the clip.
9. Disconnect the thermostat housing to radiator hose. Remove the clip.
10. Disconnect the transmission cooler hoses. Release the clip. Remove the clip.
11. Remove the coolant manifold EGR valve hose. Release the clip.
12. Disconnect both coolant manifold heater hoses. Release the 2 clips.
13. Release the coolant manifold. Remove the 4 Torx screws. Remove and discard the 3 O-ring seals.
14. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
15. Remove the coolant manifold.
16. Remove the ECT sensor. Remove the clip. Remove and discard the O-ring seal.
17. Remove the thermostat housing. Remove the 3 bolts. Discard the O-ring seal.

1. Install the thermostat housing. Clean the components. Install a new O-ring seal. Tighten the bolts to 10 Nm (7 lb.ft).
2. Install the ECT sensor. Clean the component mating faces. Install a new O-ring seal. Secure with the clip.
3. Connect the ECT sensor electrical connector.
4. Install the coolant manifold. Clean the components. Install new O-ring seals. Tighten the Torx screws to 10 Nm (7 lb.ft).
5. Connect the remaining coolant hoses. Secure with the clips.
6. Install the throttle body gasket. Refer to «Throttle Body Gasket»(/land-rover/range-rover/l322-2005-2009/remont/fuel-system/#fuel-charging-and-controls-44l) .
7. Install the cooling fan drive belt.
8. Remove the cooling fan. See «Cooling Fan»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-fan) .
9. Connect the battery ground cable. Refer to «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/charging-system/#charging-system-general-information) .
10. Refill and bleed the cooling system. See «Cooling System Draining, Filling and Bleeding»(/land-rover/range-rover/l322-2005-2009/remont/cooling-fan/#engine-cooling-44l__cooling-system-draining-filling-and-bleeding) .

See also:
• Electronic Engine Controls - Description & Operation
• Air Conditioning - Description & Operation
• Specifications
• Engine Cover - 4.4L
• Radiator Splash Shield
• Air Conditioning (A/C) System Recovery, Evacuation and Charging
• Intake Air Resonator
• Radiator Grille
• Throttle Body Gasket
• Cooling System Draining, Filling and Bleeding
• Cooling Fan