Land Rover 2000-05

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the inlet manifold chamber seals.
  6.  
  7. Remove the 2 bolts securing RH fuel rail to inlet manifold. Remove injector protection cover if equipped.
  8.  
  9. Release the 2 clips securing engine harness to rear engine lifting bracket and bracket on RH inlet manifold.
  10.  
  11. Release the clip and disconnect bottom hose from thermostat housing.
  12.  
  13. Loosen the clip and disconnect heater hose from thermostat housing.
  14.  
  15. Release the clip and disconnect top hose from coolant elbow.
  16.  
  17. Remove the bolt securing thermostat housing and coolant elbow to cylinder block.
  18.  
  19. Remove the coolant elbow from cylinder block.
  20.  
  21. Remove the thermostat housing and coolant pipe from cylinder block.

    Click image to see an enlarged view

    Fig. Exploded view of the heater hose (7), top hose (8), bolts (9), coolant elbow (10) and thermostat housing (11)

  22.  
  23. Release the clip and remove coolant pipe from thermostat housing.
  24.  
  25. Remove and discard the 4 O-rings from thermostat housing, coolant elbow and coolant pipe.
  26.  

To install:

  1. Lubricate new O-rings with clean engine oil, then install them to the sealing grooves in the thermostat housing, coolant elbow and coolant pipe.
  2.  
  3. Fit coolant pipe into thermostat housing, ensure clip connectors are uppermost.
  4.  
  5. Position thermostat housing and coolant pipe above cylinder block, engage coolant pipe in cylinder block and press thermostat housing firmly into position. Ensure mounting flange on thermostat housing is aligned to bolt hole in cylinder block.
  6.  
  7. Fit coolant elbow into cylinder block, press firmly into place. Ensure mounting flange is aligned correctly to thermostat housing flange.
  8.  
  9. Fit bolt to coolant elbow and thermostat housing flanges. Tighten bolt to 13 ft. lbs. (18 Nm).
  10.  
  11. Connect top hose to coolant elbow and secure with clip.
  12.  
  13. Connect heater and bottom hoses to thermostat housing, secure with clips.
  14.  
  15. Position and secure engine harness to brackets with clips.
  16.  
  17. If equipped, position injector protection cover to RH fuel rail, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  18.  
  19. Fit inlet manifold chamber seals.
  20.  
  21. Fill cooling system.
  22.  
  23. Connect the negative battery cable.
  24.  

  1. Drain the engine coolant to a level below the thermostat.
  2.  
  3. Remove the fan, as outlined in this section.
  4.  
  5. Unfasten the 3 clips, then disconnect the coolant hoses from the thermostat.
  6.  
  7. Remove the thermostat.

    Click image to see an enlarged view

    Fig. Unfasten the clips, then detach the hoses (3) from the thermostat (4)

  8.  

To install:

  1. Position thermostat, then connect the hoses and secure with clips.
  2.  
  3. Install the fan, as outlined in this section.
  4.  
  5. Fill the cooling system with the proper type and amount of coolant.
  6.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle with safety stands
  4.  
  5. Remove cooling fan cowl.   
  6.  
  7. Release intake hose from ducting.
  8.  
  9. Release turbocharger intake hose from ducting.
  10.  
  11. Release breather valve from intake ducting grommet.
    NOTE
    Reinstall the grommet toe the ducting

  12.  
  13. Disengage 2 clips securing intake ducting. Remove ducting.
  14.  
  15. Remove 3 bolts securing intake ducting bracket and exhaust manifold heat shield to camshaft cover. Collect bracket.
  16.  
  17. Disconnect heater hose from coolant connecting pipe.
  18.  
  19. Remove bolt securing coolant connecting pipe to engine front cover.
  20.  
  21. Remove coolant pipe.
  22.  
  23. Remove and discard the O-ring.
  24.  
  25. Remove the top hose from thermostat housing.
  26.  
  27. Remove 3 bolts securing thermostat housing to engine front cover.
  28.  
  29. Remove thermostat housing.
  30.  
  31. Collect thermostat. Remove and discard the O-ring.
  32.  
  33. Installation is the reverse of the removal procedure. Make sure the thermostat ball valve is properly positioned. Tighten the housing and pipe retaining bolts to 7 ft. lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Make sure the thermostat ball valve is properly positioned (17)

  34.  


NOTE
The thermostat heater is serviced with the thermostat and must not be removed.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the cooling system
  6.  
  7. Remove air intake hose.
  8.  
  9. Disconnect multiplug from thermostat heater.
  10.  
  11. Release clip and disconnect radiator bottom hose from thermostat housing.
  12.  
  13. Remove 4 bolts and remove thermostat housing from coolant pump. Discard seal.

    Click image to see an enlarged view

    Fig. Thermostat mounting-2003-04 Range Rover

  14.  

To install:

  1. Clean mating face of thermostat housing and coolant pump.
  2.  
  3. Position a new seal to thermostat housing.
  4.  
  5. Fit thermostat housing and tighten the bolts to 7 ft. lbs. (10 Nm).
  6.  
  7. Connect the lower radiator hose to thermostat housing and secure with clip.
  8.  
  9. Connect multiplug to thermostat heater.
  10.  
  11. Connect air intake hose.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill cooling system.
  16.  

 
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