Removal and installation a 4.0L radiator (Discovery 3)

Removal

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.

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.

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

1.

CAUTION: Never work on a vehicle supported solely by a jack. Always support the vehicle securely.

Raise and support the vehicle.

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

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

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

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

6. Remove the lower fan shroud.

• Release the 4 clamps.
• Remove the coolant hose.

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



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



(The article is based on information from the website LRMAN.RU)

9.

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

NOTE: Some liquid will inevitably spill during this operation.

Disconnect the transmission fluid cooler hoses.

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

10. Remove the radiator mounting pins.

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



12. Remove the power steering fluid cooler.

• Release the clamps.
• Move the tube to the side and tie it.

13. Remove the front differential breather hose.



14. Disconnect the air conditioner condenser.

• Remove 2 screws.
• Remove the bolt.
• Release from 2 clamps.

15. Remove the radiator.

• Protection of parts from damage is required.
• Remove 2 radiator mounting bolts.

16.

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

Remove the clamp from the power steering fluid cooler tube.

Installation

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

2. Install the radiator.

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

3. Install the upper radiator deflector.

4. Install the air conditioner condenser.

• Secure with clamps.
• Tighten the screws.
• Tighten the bolt (tightening torque 6 Nm).

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

6. Install the radiator mounting pins.

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

8. Attach the upper radiator hose. Secure with a clamp.

9. Connect the expansion tank hose. Secure with a clamp.

10. Install the lower fan shroud.

• Secure with clamps.
• Secure the coolant hose.

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

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

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