Expansion tank for cooling system 4.4L (Discovery 3)

Removal

1.

CAUTION: Never 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.

Remove the expansion tank cap.

2. Disconnect the ground cable from the battery. For more information, refer to Specification.

3.

CAUTION: Coolant may damage paintwork if it comes into contact with it. If coolant is spilled, wipe it off immediately and rinse the area with water.

Clamp and disconnect the hoses from the coolant expansion tank.

• Place an absorbent cloth to collect any spilled liquid.
• Place a container to collect the liquid.
• Release the 2 clamps.

4. Release the windshield washer reservoir filler neck from the clamp on the coolant reservoir.

5. Loosen the power steering fluid reservoir and move the reservoir to the side. Release the clamp.



6. For better access, move the vacuum pump aside.

• Remove 3 bolts.
• Remove the remaining expansion tank bracket bolt.

7. Remove the expansion tank.

• Lift the coolant expansion tank vertically together with the bracket.
• Disconnect the low coolant level sensor electrical connector.

8.

NOTE: Do not perform further disassembly if the part is removed only for access.

Remove the support bracket.

Installation

1.

NOTE: Install a new low coolant level sensor if it is not part of the new expansion tank.

Install the expansion tank on the support bracket.

2. Install the coolant expansion tank.

• Connect the low coolant level sensor electrical connector.
• Place the coolant expansion tank back in place, locating the bushing and bracket.
• Tighten the bolt (tightening torque 10 Nm).

3. Install the vacuum pump. Insert the bolts and tighten them. (tightening torque 10 Nm).

4. Install the power steering reservoir. Place it in place and secure it to the mounting bracket.

5. Install the windshield washer reservoir filler neck into place. Insert into the clamp.

6. Attach the coolant hoses to the expansion tank. Secure with clamps.

7. Top up the coolant to the required level.

• Remove the clamps from the hoses.
• Fill coolant to a level approximately 30 mm ABOVE the maximum level for cold conditions.

8. Connect the ground cable to the battery. For more information, refer to Specification.



9. Remove air from the cooling system.

• Remove the expansion tank cap.
• Connect the exhaust hoses to the rear exhaust pipes.
• Start the engine and let it run.
• Maintain the engine speed at 3000 rpm for 1 minute.
• Allow the engine to idle for 5 minutes.
• Maintain the engine speed at 3000 rpm for 1 minute.
• When performing the air removal procedure (with the expansion tank cap removed) maintain the coolant level approximately 30 mm ABOVE the maximum level when cold.

10. Check all coolant hoses for obvious signs of coolant leakage.

11. Install the expansion tank cap after ensuring that the final coolant level is 30 mm above the maximum level when cold.