Discovery 2. Manual — part 176

STEERING

REPAIRS

57-39

Refit

1. Clean seal recess, output shaft, end cover and

mating face.

2. Lubricate new end cover 'O' ring with clean

PAS fluid. Fit 'O' ring to end cover.

3. Position output shaft, fit bolts and tighten to 88

Nm (65 lbf.ft).

4. Tighten rack adjuster one turn, align marks and

secure with Allen screw.

5. Lubricate new output shaft seal with clean PAS

fluid.

6. Fit seal using LRT-57-504.
7. Fit spacer, circlip and seal shield.
8. Clean drop arm and steering box splines.
9. Ensure steering box is in the central position.

Align and fit drop arm to output shaft and
secure with new lock washer and nut. Tighten
nut to 240 Nm (177 lbf.ft).

10. Secure lock washer to drop arm nut.
11. Fit steering box.

l

For V8 models:

+

STEERING, REPAIRS, Power

steering box - V8.

l

For LHD diesel models:

+

STEERING, REPAIRS, Power

steering box - LHD - diesel.

l

For RHD diesel models:

+

STEERING, REPAIRS, Steering

box - RHD - diesel.

Pump - power steering - V8

$% 57.20.14

Remove

1. Remove auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

2. Remove cable tie securing harness to air intake

hose.

3. Loosen 3 clips securing air intake hose, release

and remove hose.

Note: Pre 03 MY air intake hose illustrated.

4. Models with ACE: Remove 3 bolts securing

ACE pump, release pump and position aside.

STEERING

57-40

REPAIRS

5. Models with A/C: Disconnect A/C compressor

multiplug. Remove 4 bolts securing A/C
compressor, release compressor and position
aside.

6. Remove 3 bolts securing PAS pump pulley and

remove pulley.

7. Position tray to catch spillage, release PAS

pump pressure pipe.

8. Remove clip and release PAS pump inlet hose.

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

9. Remove jockey pulley.

10. Remove bolt securing oil cooling pipe bracket

and release bracket from housing.

11. Remove two bolts securing PAS pump.
12. Remove 4 bolts and one nut securing auxiliary

housing. Pull housing forward and release
PAS pump. Remove PAS pump.

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.

STEERING

57-42

REPAIRS

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.

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.