Removal and installation a 2.7L radiator (Discovery 3)

Removal

For all cars

1.

CAUTION: Do not work on or under a vehicle supported solely by a jack. Always support the vehicle with jack stands.

Raise and support the vehicle.

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

3. 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 a burn.

Drain the coolant from the cooling system. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)

4. Remove the lower cooling fan shroud. For more information, refer to Cooling Fan Shroud (26.25.11)

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

6. Remove the left headlamp assembly. For more information, refer to Headlamp Assembly (86.40.49)

7. Remove the coolant expansion tank. Unscrew the 2 bolts.



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



9. Remove the right front fender splash guard. Remove the 4 clips.





10.

CAUTION: To avoid contamination of the system, always plug all open connections.

Disconnect the charge air cooler inlet hose.

• Release the clamp.
• Move it aside and tie it up.

11.

CAUTION: To avoid contamination of the system, always plug all open connections.

Disconnect the charge air cooler outlet hose.

• Release the clamp.
• Move it aside and tie it up.

12. Disconnect the upper radiator hose.

• Release the clamp.
• Move it aside and tie it up.

13. Disconnect the lower radiator hose.

• Release the clamp.
• Move it aside and tie it up.

14. Move the engine air intake towards the engine and tie it down.

Cars with automatic transmission

15.

CAUTION: To avoid contamination of the system, always plug all open connections.

Disconnect the 2 transmission fluid cooler pipes.

• Release the clamps.
• Place a container to collect any spilled liquid.
• Move it aside and tie it up.

For all cars

16. Disconnect the fuel cooler line. Release the clamp.

17. Remove the radiator mounting pins. Release the clamps.

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

19. Remove the power steering fluid cooler.

• Release the 2 clamps.
• Move the hose to the side and tie it.

20. Remove the front differential breather hose.



21. Remove the power steering fluid cooler tube retaining clamp.



22. Remove the air conditioner condenser.

• Remove 3 bolts.
• Release the 2 clamps.

23. Release the radiator.

• Remove 2 bolts.
• Lift the radiator to remove it from its mountings.

24. Tilt the air conditioner condenser forward, away from the radiator.

25.

NOTE: Left side shown, right side similar.

Remove the 2 clamps that secure the radiator to the charge air cooler.

26.

CAUTION: When performing this operation, it is necessary to protect the radiator.

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

Carefully remove the radiator.

27.

NOTE: Mark the installation position.

Remove the fuel cooler hose. Release the clamp.

28. Remove the lower radiator deflector.

29. Remove the radiator rubber mounts.

Installation

For all cars

1. Install the radiator rubber mounts.

2. Install the lower radiator deflector.

3. Install the fuel cooler hose. Tighten the clamp.

4.

CAUTION: When performing this operation, it is necessary to protect the radiator.

Carefully install the radiator.

5. Install the 2 clamps that secure the radiator to the charge air cooler.

6. Align the radiator.

• Lift the radiator onto its mounts.
• Tighten the bolts (tightening torque 25 Nm).

7. Connect the air conditioner condenser.

• Remove and discard 2 wire ties.
• Lift the knot into the clamps.
• Tighten the bolt (tightening torque 6 Nm).

8. Install the front differential breather hose.

9. Install the power steering fluid cooler. Secure with 3 clamps.

10. Install the upper radiator deflector.

11. Install the radiator mounting pins.

12. Connect the fuel cooler line. Secure with a clamp.

Cars with automatic transmission

13. Connect the transmission fluid cooler hoses. Install the clamps.



For all cars

14. Install the lower radiator hose. Secure with a clamp.

15. Release the air intake. Remove and discard the wire tie.

16. Connect the upper radiator hose.

• Remove and discard the wire tie.
• Secure with a clamp.

17. Connect the lower radiator hose.

• Remove and discard the wire tie.
• Secure with a clamp.

18. Attach the charge air outlet hose. Tighten the clamp. (tightening torque 10 Nm).

19. Attach the charge air inlet hose. Tighten the clamp. (tightening torque 10 Nm).

20. Install the right front fender splash guard. Install 4 clips.

21. Secure the coolant expansion tank. Tighten the two mounting bolts. (tightening torque 10 Nm).

22. Attach the radiator bleed hose. Secure with a clamp.

23. Install the left headlamp assembly. For more information, refer to Headlamp Assembly (86.40.49)

[Information obtained from the website lrman.ru]

24. Install the radiator grille. For more information, refer to Radiator Grille (76.55.03)

25. Install the lower cooling fan shroud. For more information, refer to Cooling Fan Shroud (26.25.11)

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

27. Fill the cooling system with coolant. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)

Cars with automatic transmission

28. Check the transmission fluid level in the automatic transmission.