4.0 Discovery 2 trials & tribulations

[Eddie Honda]

That's what I'll know will happen!

[John F]

OK, the Disco is now finished*.

Now pub.

Slightly disappointing pics (phone died half way through fitting the new PAS pump) to follow tomorrow.

[John F]

(Soz, I had problems attaching the pics so here's my post again...)

Herewith the pics as promised.

Here's the duff NSF hub. The ABS wires had been chopped, soldered & taped... now returned to standard with a proper terminal on the engine loom.

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New shiny hub complete with new ABS sensor:

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This job is much easier than on the Discovery 1 since the bearings & ABS sensor are now all contained within the hub, which is replaced as a single unit. It's just held on by four bolts (fitted from behind, i.e. facing outwards) and the drive shaft nut.

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New hub fitted - final torque will be applied to the drive shaft nut when the wheel is back on the floor:

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Disc fitted:

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All four discs were changed, all callipers & calliper carriers were serviced. One of the rear callipers was partially seized (no pic, but water ingress under the bellows had rusted the piston so it wouldn't push all the way home), and this seems to have warped the disc - a bloody shame, since the rear was fitted with slotted & drilled discs & Green Stuff brake pads that had LOADS of life left in them

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Cleaned & greased calliper carrier:

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All pads copper-greased & fitted with anti-rattle plates:

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Right, now moving on to the PAS leak. The bonnet is full of engine...

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I've never worked on a V8 before and don't have a manual - WCPGW? Nothing, as it turned out. Although I had plenty of cause to swear at Land Rover's designers... more of that later.

As you look at the engine from in front of the car, the PAS pump lives down at the bottom on the right underneath the Active Cornering Enhancement (ACE) pump. It's in the shadow at the bottom of this really unhelpful picture:

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(see continuation below)

[John F]

Hmmm, it looks as if the forum is set to only allow a maximum number of 10 pics in one post. Hooli, could you confirm that?

Anyway, on with the tale.

The new pump came in a refreshingly non-blue package. Even better, I'd only paid for an unbranded item but it was packed in a Bearmach box.

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With the viscous fan cowl, viscous fan and top pulley covers removed, the serpentine belt and all its consumers could be seen. In this pic we have, top to bottom, left to right; alternator, aircon pump, ACE pump, tensioner, crank (and viscous fan) pulley, idler pulley, PAS pump, then a final idler at bottom left.

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Here's a better pic of the PAS pump pulley. It's at bottom right:

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With the pulley bolts cracked & serpentime belt removed, the PAS pulley could be removed, and then the PAS pump is visible. It's only mounted on two bolts, one either side, plus a stud at the top in the centre and also the low-pressure hose to the reservoir (jubilee clip) and the high-pressure hose to the steering box (16 mm threaded connector). should be nice & easy to finish the job now, right? RONG!

Look at this pic.

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The two bolts either side of the PAS pump have been removed, but the central stud can clearly be seen above the PAS pump flange. The cunts at LR decided, in their infinite wisdom, to trap the top of the PAS pump, i.e. the bit that this stud passes through, under a casting that supports the ACE pump and the aircon pump...! What on earth couldn't they have just used a fucking BOLT? The ACE pump (and its hose bracket) and the aircon pump had to be loosened so the casting could be removed from the vehicle together with the PAS pump, adding four bastarding hours and a metric shitload of swearing to the job. And yes, I did try to unwind the stud with two M8 nuts clamped together, but there wasn't really enough exposed thread (or access for spanners) to make that work.

My phone battery died at this point, so there are no pics of the remaining steps. But the job went OK after this, just fitting the the new PAS pump, the casting, the aircon pump, the ACE pump and its hose bracket and the new serpentine belt in the reverse order of removal. The old serpentine belt had stretched but was still serviceable, so it's been kept as an emergency belt.

The low-pressure and high-pressure hoses were then fitted to the new PAS pump and the reservoir was filled with PAS fluid. Then the engine was started & the system purged of air by bouncing the steering off the end limit stops a few times, fluid topped up & then a check made for leaks... none spotted. And the engine runs nice & quietly now, no screeching and squeaking from the PAS pump

Covers & viscous fan replaced, job jobbed. The only thing that still needs attention is the slightly-sticking rear calliper. I'm not happy with it, the rest of the brakes are now in top condition & I don't want to spoil the car for the sake of £26.95 - which is the cost of the one I've just ordered. New calliper due to arrive on 17th December.

[Hooli]

They are still a version of the Rover V8 at this age aren't they?

[John F]

Yep, still essentially the same engine underneath.

[Hooli]

I thought so, was hard to tell under all that gumph though.

[John F]

So is there a 10-picture limit in posts, Andy? And if so, can it be increased? 10 isn't enough for even a fairly small job like this.

[Hooli]

Yes I think there is & yes it could, I was thinking of changing that once I got the resizing bit working. I need to swear at the SSH access again though.

[John F]

Wowsers! The new calliper has arrived already. It wasn't all that long back when anything took weeks or even months to arrive around xmas time, now it's less than 2 days.

I'll bung some charge in the Disco's battery, then I might find time to pop the calliper on later today.