Removal and installation of a radiator 4.0L (Discovery 3)

Removing

WARNING: Do not remove the coolant expansion tank cap when the system is hot, as steam or coolant escaping from the cap could cause serious injury such as scalding.

WARNING: Coolant that comes into contact with the paintwork can damage it. If you spill coolant, remove it immediately and flush the area with water.

NOTE: Always protect the heatsink assembly parts from accidental damage.

1.

WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Always place the vehicle on secure stands.

Raise and support the vehicle.

2. Disconnect a wire of weight from the accumulator. For more information refer to Specification.

3. Drain the liquid from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

4. Remove the viscous fan assembly. For more information refer to Cooling Fan (26.25.19)

5. Remove the grille. For more information refer to Radiator Grille (76.55.03)

6. Remove the lower fan shroud.

• Release 4 clamps.
• Remove the coolant hose.

7. Disconnect the expansion tank hose. Release the clamp.


8. Disconnect the upper radiator hose. Release the clamp.



9.

WARNING: Plug all open connections to avoid contamination of the system.

NOTE: Some liquid will inevitably spill during this operation.

Disconnect the transmission fluid cooler hoses.

• Release 2 clamps.
• Place a container to catch spilled liquid.

10. Remove the radiator mounting pins.

11. Remove the upper radiator deflector. Release 2 clamps.



12. Remove the power steering fluid cooler.

• Release the clamps.
• Take the tube aside and tie.

13. Remove the front differential breather hose.



14. Disconnect the conditioner condenser.

• Remove 2 screws.
• Turn out a bolt.
• Release from 2 clips.

15. Remove the radiator.

• Parts must be protected from damage.
• Turn out 2 bolts of fastening of a radiator.

16.

NOTE: Do not proceed with further disassembly if the part is being removed only for access.

Remove the clamp from the power steering fluid cooler pipe.

Installation

1. Install the clamp on the power steering fluid cooler tube.

2. Install the heatsink.

• Remove the protective devices from the parts.
• Tighten the bolts (tightening torque 25 Nm).

3. Install the upper radiator deflector.

4. Install the air conditioning condenser.

• Fasten in clamps.
• Tighten the screws.
• tighten bolt (tightening torque 6 Nm).

5. Install the power steering fluid cooler. Secure with three clips.

6. Establish pins of fastening of a radiator.

7. Attach the transmission fluid cooler hoses. Install clamps.

8. Attach the upper radiator hose. Fasten with a clip.

9. Connect a hose of a broad tank. Fasten with a clip.

10. Install the bottom fan shroud.

• Fasten in clamps.
• Attach the coolant hose.

11. Install the grille. For more information refer to Radiator Grille (76.55.03)

12. Install the viscous fan assembly. For more information refer to Cooling Fan (26.25.19)

13. Fill in cooling liquid in the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (26.10.01)

14. Connect a wire of weight to the storage battery. For more information refer to Specification.

15. Check the transmission fluid level in the automatic transmission. For more information, refer to Checking the Transmission Fluid Level (44.24.06)