Thread: Removing a radiator from a Disco TD5

Hi Jo,

Start with removing the top shroud - 4 Phillips screws, then you'll need a 36mm spanner to remove the viscous fan - a sharp tap anticlockwise as you're facing the vehicle should see it come loose and then unwind by hand.

Once you know the fans coming off you can then drain the system by undoing the plug on the lower rail, don't over tighten when replacing this, I also use some thread sealant on this when it goes back in. The lower shroud will now come out - it just clips into a rail on the bottom of the radiator.

You need to remove the front grill, easy on a d2a but I think the headlights need to come out on the earlier models to get to the grill mounting bolts.

The horns then need to come out from memory and then you can get access to the radiator mounting brackets. Unclip the hoses to the rad, undo the mounting bolts for the rad and you should be able to wriggle it out, mine an auto with oil cooler and I got the rad out without removing that. What you then have out of the car is the radiator with the intercooler attached (worth flushing this out if it looks dirty)

Swap over the intercooler and other mounting bits/strips to the new rad and reverse the above to install. Have a beer either during or after the battle with the hose clips Leave the top shroud off so you can check for leaks later.

To fill the system up you'll need to raise the expansion tank, undo the bleed screw on the top hose and fill up slowly until the coolant is coming out of the bleed screw, tighten the screw up and then Give the hoses a squeeze to release some air then place the expansion tank back in its place. I idle the engine a few minutes to let the air bubbles bleed out, and keep an eye on the tank level as well when doing this. Go for a drive and then check for leaks, if you hear bubbles the there's still air in the system so try bleeding it again.

It takes about 2.5-3 hrs all in. Have fun

Rich