Land Rover 2000-05

Removal & Installation

Print

  1. Disconnect the negative battery cable.
  2.  
  3. Remove engine acoustic cover.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. On models without A/C, perform the following:
    1. Remove the bumper valance.
    2.  
    3. Remove 2 bolts securing PAS fluid cooler to armature.
    4.  
    5. Remove 4 nuts and 4 bolts securing armature to body and remove armature.
    6.  

  8.  
  9. On models with A/C, remove the A/C condenser.
  10.  
  11. Release the hose clips, then disconnect the upper and lower radiator hoses.
    WARNING
    Always cap or plug open connections to prevent contamination from entering the cooling system.



    Click image to see an enlarged view

    Fig. Release the hose clips, then disconnect the upper and lower radiator hoses

  12.  
  13. Release clip and remove expansion hose from radiator.
  14.  
  15. If equipped, remove the 2 bolts and 4 scrivets securing LH and RH radiator baffles and remove baffles.

    Click image to see an enlarged view

    Fig. If equipped, remove the 2 bolts and 4 scrivets securing LH and RH radiator baffles and remove baffles

  16.  
  17. Remove the radiator upper retaining pegs from hood locking platform. Ease the top of the radiator forward.
  18.  
  19. Remove 4 bolts securing fan cowl to radiator.

    Click image to see an enlarged view

    Fig. Unfasten the 4 fan cowl-to-radiator bolts

  20.  
  21. Remove the 2 cowl retaining clips from the radiator.

    Click image to see an enlarged view

    Fig. Remove the 2 cowl retaining clips from the radiator

  22.  
  23. Release radiator from lower mountings and remove from vehicle.
  24.  
  25. Remove radiator upper mounting extension brackets.

    Click image to see an enlarged view

    Fig. Remove radiator upper mounting extension brackets

  26.  
  27. Remove the 4 rubber mountings from radiator.
  28.  

To install:

  1. Fit mounting rubbers to radiator.
  2.  
  3. Fit upper support brackets to radiator.
  4.  
  5. Position fan cowl to radiator, fit and tighten bolts to 4 ft. lbs. (5 Nm).
  6.  
  7. Secure the fan cowl to the radiator with clips.
  8.  
  9. Install the radiator and engage lower mountings in chassis.
  10.  
  11. Install the radiator upper mountings to the hood locking platform.
  12.  
  13. If equipped, position LH and RH radiator baffles, secure with scrivets, fit and tighten the top bolts to 4 ft. lbs. (5 Nm).
  14.  
  15. Connect expansion tank hose and secure with clip.
  16.  
  17. Connect bottom and top hoses to radiator secure with clips.
  18.  
  19. If equipped, install the A/C condenser.
  20.  
  21. On models without A/C, perform the following:
    1. Position armature, fit and tighten 4 nuts and bolts securing armature to body.
    2.  
    3. Align the PAS fluid cooler and tighten bolts to 6 ft. lbs. (8 Nm).
    4.  
    5. Fit the bumper valance.
    6.  

  22.  
  23. Refill cooling system.
  24.  
  25. Install the acoustic cover.
  26.  
  27. Connect the negative battery cable.
  28.  

  1. Remove the retainers and the battery cover.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the coolant into a suitable container.
  6.  
  7. Remove the upper fan cowl.
  8.  
  9. Remove the 2 screws retaining the lower half of the fan cowl, then remove the cowl.
  10.  
  11. Unfasten the clip and disconnect the upper radiator hose from radiator.
  12.  
  13. Unfasten the clip and disconnect the bleed hose from radiator.

    Click image to see an enlarged view

    Fig. Unfasten the screws (5), then remove the cowl. Detach the clip and the upper radiator hose (6), then unfasten the clip and disconnect the bleed hose (7)

  14.  
  15. Remove the front grille.
  16.  
  17. Disconnect the connector from the gearbox oil temperature sensor.
  18.  
  19. For 2000-02 vehicles, remove the clips, then remove the air deflectors from front panel.

    Click image to see an enlarged view

    Fig. Remove the clips and the air deflectors (9)-2000-02 Discovery models

  20.  
  21. For 2003-04 models, drill out the 6 scrivets, then remove the air deflectors from the front panel.

    Click image to see an enlarged view

    Fig. Drill out the rivets and remove the air deflectors (9)-2003-04 Discovery models

  22.  
  23. Remove the retainers and the horns.

    Click image to see an enlarged view

    Fig. Unfasten the retainers, then remove the horns

  24.  
  25. Move the sound-deadening material from behind each horn aside.
  26.  
  27. Remove 2 bolts securing radiator RH and LH upper mounting brackets to body panel and remove brackets.
  28.  
  29. Remove 4 screws securing air conditioning condenser RH and LH upper mounting brackets to condenser.
  30.  
  31. Remove brackets with rubber mounts from radiator extension brackets.

    Click image to see an enlarged view

    Fig. View of the left and right upper mounting brackets (12), screws holding the A/C compressor brackets (13) and brackets (14)

  32.  
  33. Position a rag or catch pan under gearbox cooler hose connection to collect spillage.
  34.  
  35. Release the quick release connector, then disconnect the gearbox fluid cooler pipe from the gearbox fluid cooler.
  36.  
  37. Remove right and left side radiator extension bracket air deflector securing bolts, then remove the air deflectors.
  38.  
  39. Remove the 2 bolts securing the radiator upper mounting brackets to the body panel and remove brackets.
  40.  
  41. Move gearbox oil cooler aside.
  42.  
  43. Move engine oil cooler aside.
  44.  
  45. Position suitable protection between radiator and cooling fan.
  46.  
  47. Release the radiator from lower mountings and carefully remove it from the vehicle.
  48.  
  49. Remove 2 retaining nuts from radiator.
  50.  
  51. Remove sealing strip from radiator.
  52.  
  53. Remove 2 cowl retaining clips from radiator.
  54.  
  55. Remove rubber mountings from base of radiator.

    Click image to see an enlarged view

    Fig. Remove the 2 retaining nuts (23), sealing strip (24), cowl clips (25) and rubber mounts (26) from the radiator

  56.  

To install:

  1. Install the rubber mountings, cowl clips, sealing strip and 2 nuts to the radiator.
  2.  
  3. Position the radiator in the vehicle, and fit the lower mountings in place in the chassis.
  4.  
  5. Install the engine oil cooler and gearbox oil cooler.
  6.  
  7. Install the radiator air deflectors and brackets.
  8.  
  9. Install the brackets with rubber mounts to the radiator extension brackets.
  10.  
  11. Install the upper mounting brackets to the condenser.
  12.  
  13. Install the upper mounting brackets to the front panel.
  14.  
  15. Remove protection from between the radiator and cooling fan.
  16.  
  17. Make sure the connections are clean and connect the hose to gearbox cooler.
  18.  
  19. Fit sound-deadening back into position.
  20.  
  21. Install the horns.
  22.  
  23. Connect the connector to the gearbox oil temperature sensor.
  24.  
  25. Install the air deflectors in the front panel.
  26.  
  27. Install the front grille.
  28.  
  29. Connect the radiator bleed hose.
  30.  
  31. Connect the radiator upper and lower hoses and secure with the clips..
  32.  
  33. Position the lower half of fan cowl and secure with screws.
  34.  
  35. Install and secure upper fan cowl.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Install the battery cover.
  40.  
  41. Fill the cooling system.
  42.  
  43. Check the gearbox oil level, and add as necessary.
  44.  
  45. Start the engine and check for leaks. Check the fluid levels, and add if necessary.
  46.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the coolant into a suitable container.
  6.  
  7. Release clips securing upper cooling fan cowl and remove the cowl.
  8.  
  9. Disconnect the upper radiator hose
  10.  
  11. Remove the expansion tank hose from radiator.
  12.  
  13. Remove the lower radiator hose.
  14.  
  15. Remove the bolts securing radiator to bracket. Remove radiator assembly.
  16.  

To install:

  1. Inspect radiator drain plug O-ring, and replace if necessary.
  2.  
  3. Install the drain plug to radiator and tighten to 4 ft. lbs. (6 Nm)
  4.  
  5. Carefully lower vehicle.
  6.  
  7. Disconnect radiator bleed hose at the radiator.
  8.  
  9.  Blow through hose to clear any residual coolant. Reconnect hose.
    WARNING
    If radiator bleed hose is not cleared of coolant, air may become trapped at top of radiator during refill, leading to subsequent engine overheating.

  10.  
  11. Fill the expansion tank until coolant is level with base of neck.
  12.  
  13. Start the engine, continue filling at expansion tank until coolant level stabilizes at the COLD LEVEL mark.
  14.  
  15.  Run the engine until the thermostat opens (top hose becomes warm).
  16.  
  17. Stop engine, and allow to cool.
  18.  
  19. Check coolant level and top-up as necessary.
  20.  
  21. Refit the expansion tank filler cap.
  22.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle..
  4.  
  5. Drain cooling system.
  6.  
  7. Remove fan cowl.
  8.  
  9. Remove screw and release gearbox cooler manifold from radiator.
  10.  
  11. Release the hose clips and disconnect the upper and lower radiator hoses and the expansion tank hose from radiator.
  12.  
  13. Remove radiator assembly retaining bolts from hood locking platform.
  14.  
  15. Ease radiator assembly rearward, release and remove radiator retaining clips, then carefully remove the radiator.

    Click image to see an enlarged view

    Fig. Remove the radiator assembly retaining bolts from hood locking platform. Ease radiator assembly rearward, release and remove radiator retaining clips, then carefully remove the radiator

  16.  

To install:

  1. Position radiator to mounting, fit and secure retaining clips.
  2.  
  3. Position and secure radiator assembly to bonnet locking platform.
  4.  
  5. Position gearbox cooler to radiator and tighten securing screw.
  6.  
  7. Connect hoses to radiator and secure with clips.
  8.  
  9. Fit viscous coupling, as outlined under Engine Fan.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Fill the cooling system.
  14.  
  15. Start the engine and check for leaks. Check the fluid levels, and add if necessary.
  16.  

 
label.common.footer.alt.autozoneLogo