Discovery 2. Manual — part 598

STEERING

REPAIRS

57-41

Refit

1. Position PAS pump to auxiliary housing and

locate housing to engine. Fit and tighten
auxiliary housing bolts to 40 Nm (30 lbf.ft).

2. Tighten auxiliary housing nut to 10 Nm (7 lbf.ft).
3. Fit bolts securing PAS pump and tighten to 22

Nm (16 lbf.ft).

4. Position PAS pump pipe bracket, fit and tighten

bolt to 22 Nm (16 lbf.ft).

5. Fit and tighten PAS pump pressure pipe.
6. Fit PAS pump inlet hose and secure with clip.
7. Position jockey pulley and tighten bolt to 50 Nm

(37 lbf.ft).

8. Clean PAS pump pulley mating faces.
9. Position PAS pump pulley, fit bolts and tighten

to 22 Nm (16 lbf.ft).

10. Models with ACE: Clean ACE pump dowels

and dowel holes. Position ACE pump, fit bolts
and tighten to 25 Nm (18 lbf.ft).

11. Models with A/C: Clean A/C compressor

dowels and dowel holes. Position A/C
compressor, fit bolts and tighten to 22 Nm (16
lbf.ft).

12. Position air intake hose and secure with clips.
13. Secure harness to air intake hose with new

cable tie.

14. Fit auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive..

15. Bleed PAS system.

+

STEERING, ADJUSTMENTS,

Hydraulic system - bleed.

Pump - power steering - diesel

$% 57.20.14

Remove

1. Remove auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

2. Remove 3 bolts securing PAS pump pulley and

remove pulley.

3. Position tray to catch spillage, release PAS

pump pressure pipe.

4. Remove clip and release PAS pump inlet hose.

CAUTION: Always fit plugs to open
connections to prevent contamination.

5. Remove 4 bolts and remove PAS pump.

6. Remove bolt, and remove mounting bracket

from PAS pump.

7. Remove 2 bolts, remove low pressure adaptor

pipe and discard 'O' ring.

STEERING

57-42

REPAIRS

Refit

1. Clean PAS pump and adaptor pipe.
2. Fit new 'O' ring to adaptor pipe, fit pipe and

tighten bolts to 10 Nm (7 lbf.ft).

3. Position mounting bracket to PAS pump, fit but

do not tighten bolt.

4. Position PAS pump and align pump drive to

coolant pump. Fit and tighten bolts to 25 Nm
(18 lbf.ft).

5. Tighten mounting plate bolt to 25 Nm (18 lbf.ft).
6. Clean PAS pump and pipe union.
7. Fit and tighten PAS pump pressure pipe to 20

Nm (15 lbf.ft).

8. Fit PAS pump inlet hose and secure with clip.
9. Clean PAS pump and pulley mating faces.

10. Position PAS pump pulley, fit and tighten bolts

to 10 Nm (7 lbf.ft).

11. Fit auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

12. Bleed power steering system.

+

STEERING, ADJUSTMENTS,

Hydraulic system - bleed.

Steering column assembly and lock

$% 57.40.01

Remove

1. Remove steering column intermediate shaft.

+

STEERING, REPAIRS, Shaft -

intermediate and universal joint - steering
column.

2. Remove rotary coupler.

+

RESTRAINT SYSTEMS, REPAIRS,

Rotary coupler.

3. Open fascia lower access panel.
4. Remove steering column nacelle.

+

STEERING, REPAIRS, Nacelle -

steering column.

5. Disconnect multiplug and illumination bulb

from passive coil and remove passive coil.

STEERING

REPAIRS

57-43

6. Disconnect 2 multiplugs from wiper switch

assembly.

7. Disconnect 2 multiplugs from light switch

assembly.

8. Loosen screw and remove switch assembly.
9. Disconnect ignition switch multiplug.

10. Disconnect multiplug from ignition switch

housing.

11. Release harness from column clip.
12. Remove 4 nuts securing steering column

assembly to fascia rail and remove steering
column assembly.

13. Remove rubber boot from steering column

assembly.

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.