Land Rover Discovery: Engine Cooling - Ingenium i4 2.0l Diesel / Diagnosis and Testing

PRINCIPLES OF OPERATION

For a detailed description of the Engine Cooling system, refer to the relevant Description and Operation section in the workshop manual.

REFER to: Engine Cooling (303-03B Engine Cooling - INGENIUM I4 2.0L Diesel, Description and Operation).

INSPECTION AND VERIFICATION

WARNING:

Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn. Cover the expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury.

CAUTIONS:

• The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the engine.
• Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.
• Never remove the coolant expansion tank cap under any circumstances while the engine is operating. Failure to follow this instruction may result in damage to the engine.
• Diagnosis by substitution from a donor vehicle is NOT acceptable.

  Substitution of control modules does not guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.

NOTES:

• If a control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation of a new module/component.
• When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with an up-todate calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into account.
• Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

1. Verify the customer concern
2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection

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. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index
5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific customer complaint and carry out the recommendations as required

SYMPTOM CHART

SYMPTOM:

Coolant loss

POSSIBLE CAUSES:

• Coolant hose(s) leaking
• Coolant hose connection(s) leaking
• Radiator leaking
• Variable coolant pump leaking
• Heater core leaking
• Seals leaking
• Engine casting leaking
• Engine core plugs leaking

ACTION:

GO to Pinpoint Test A.

SYMPTOM:

Engine overheating

POSSIBLE CAUSES:

• Coolant level low
• Thermostat flow/direction valve fault
• Electric cooling fan inoperative
• Engine coolant temperature sensor fault
• Radiator airflow restricted

ACTION:

• GO to Pinpoint Test B.

SYMPTOM:

Engine not reaching normal operating temperature

POSSIBLE CAUSES:

• Thermostat flow/direction valve fault
• Electric cooling fan stuck on

ACTION:

• GO to Pinpoint Test C.

SYMPTOM:

Message centre displays "Coolant Level Low" warning message

POSSIBLE CAUSES:

• Coolant loss
• Engine coolant level sensor fault
• Engine coolant level sensor circuit fault

ACTION:

• GO to Pinpoint Test D.

COMPONENT TESTS

COOLING SYSTEM PRESSURE TEST

WARNING:

Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine and/or cause personal injury.

1. Switch the engine off
2. Open the hood and install protective fender covers
3. Carefully remove the coolant expansion tank pressure cap from the coolant expansion tank to relieve pressure in the cooling system. Add coolant to coolant expansion tank as necessary
4. Install the pressure tester equipment to the cooling system following manufacturers instructions. Reinstall the coolant expansion tank pressure cap (if pressure test equipment is not installed to the coolant expansion tank)
5. Pressurize the cooling system to the coolant expansion tank pressure cap lower limit
6. Observe the gauge reading for approximately two minutes. Pressure should not drop during this time

• If system holds pressure, continue from step 7
• If the pressure drops, check the complete cooling system for leaks. Also refer to engine system checks if a leak cannot be located in the cooling system. Correct any leaks found and recheck the system

7. Release the system pressure and remove the pressure test equipment.

   Check the coolant level. Replenish as necessary with the correct coolant solution

8. Check the radiator overflow hose for any obstructions which may block the flow of coolant either to or from the coolant expansion tank
9. Conduct the coolant expansion tank pressure cap pressure test in this section

COOLANT EXPANSION TANK PRESSURE CAP PRESSURE TEST

WARNING:

Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine and/or cause personal injury.

1. Remove the expansion tank pressure cap from the coolant expansion tank
2. Use water to clean cap in area of rubber seal and vacuum relief valve.

   Following manufacturers instructions, install the coolant expansion tank pressure cap to the pressure tester

NOTE:

If the pressure tester is pressurised too quickly, an erroneous pressure reading may result.

3. Slowly pressurise the system until the pressure gauge reading stops increasing, and note highest pressure reading obtained
4. Release pressure and repeat Step 3 at least twice to make sure the pressure test reading is repeatable and within specification
5. If the pressure test gauge readings are not within specification, install a new coolant expansion tank pressure cap

THERMOSTAT TEST

Check the electric thermostat for loose or corroded connector(s), check the operation of the electric flow/direction valve(s). If the engine still does not maintain the correct temperature, suspect the operation of the internal wax type thermostat. Check and replace parts as necessary

RADIATOR LEAK TEST - REMOVED FROM THE VEHICLE

CAUTION:

Do not leak test an aluminium radiator in the same water that is used to leak test copper/brass radiators. Flux and caustic cleaners may be present in the test water which will corrode aluminium. If a separate tank is not available, drain and rinse the test tank before testing an aluminium radiator.

Clean the radiator before leak testing to prevent contamination of the test tank. Leak test the radiator in clean water with 138 kPa (20 psi) air pressure

PINPOINT TESTS

WARNING:

The cooling system is pressurized! Ensure the reservoir cap is never released until the system has cooled. Failure to follow these instructions may result in personal injury.

WARNINGS:

• DO NOT remove the coolant expansion tank cap when the engine is hot. Failure to follow this instruction may result in personal injury.
• Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine and/or cause personal injury.

DTC INDEX

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00. REFER to: Diagnostic Trouble Code Index - INGENIUM I4 2.0L Diesel, DTC: Engine Control Module (ECM) B10A2-07 to P034B-76 (100-00 General Information, Description and Operation).

Engine Cooling - Ingenium i4 2.0l Diesel Specifications

Lubricants, Fluids, Sealers and Adhesives

NOTE:

Coolant must be collected into a clean container and can be reused if not contaminated.

Capacities

General Specification

Torque Specifications

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