Hey there, I replaced the brittle expansion tank on my Disco 2 today and took pictures of the process. No terrible, messy draining of the coolant system required. It was one of those rare things that went well - almost no spill, no draining coolant, no breaking things, no real hiccups. It is really a straightforward process. This writeup is just to show how I did it and it went well.

Tools recommended:
- Fluid line clamps (Check out photo below)
- Fluid extractor / pump
- Catch pan for coolant extracted from tank
- Paper towels / rags for spillage
- Sockets/screwdrivers to remove hose clamps (depending on what clamps you have)
- Picks to help get off old hoses



Here was the status of my old, brittle coolant tank and tank cap:




New tank and cap from FCP Euro:
Tank - https://www.fcpeuro.com/products/rov...behr-pcf101410
Cap - https://www.fcpeuro.com/products/lan...over-pcd000070

Process:

1. Unhook, unclip expansion tank from its position and raise up
2. Clamp large bottom hose



3. Clamp smaller hose that feeds from bottom



4. Pump out coolant from tank using fluid pump into catch pan. You have to tilt the tank as much as you can towards the rear of the car (near the cap) since the tube will not go to the bottom of the other side where it is deepest. Get as much out as you can. I got almost all of it.



5. Place paper towels underneath small bottom hose and remove the hose from the old tank



6. Do the same for the large bottom hose



7. Unclip and remove top return hose (on the tank cap area closest to the front of the car). Other one is just a drain hose and is connected to nothing. I did not bother clamping the hose and I don't think any coolant came out of it.

8. Remove old tank



9. Reinstall bottom hose onto new tank first - If you took off the original hose clamp after loosening it, put it back on. Put hose onto plastic - release hose clamp tool - push hose on all the way - tighten hose down onto plastic.



10. Do the same for the smaller bottom hose (Again, don't forget the original hose clamp)



11. After putting on both bottom hoses and removing the hose clamp tools, reposition the tank into its slot and clip it down. Mine felt a little different size but I got it back in. Put on the top return hose and re-clamp it with original clamp.



12. With the clamp tools released, the tank refilled quite a bit. Here is how little coolant I lost:



13. Top off the coolant level with 50/50 conventional green coolant (if you're not using this you probably should be -- conventional green or anything that is not dex-cool). I had some lying around.



14. Put on your new tank cap (or the old if it is in good shape) and you're done! Be sure to frequently check the coolant level and top off if you need to during the next few drives. (Just don't do it while engine is hot of course.)

P.S. If you don't have the inline thermostat mod, I would do that almost before anything else. See the sticky on the D2 homepage.

 

That Behr/Mahle tank is the best for the money by far. Much better quality than other brands. That's what I have now.

 

Yeah I was surprised to find it so cheap and that it was made by Mahle. Almost hard to believe but I know FCP Euro is a good company. Have you had it a while?

 

I replaced it this past spring. I've gone through at least 2 others since I've owned the truck. This one is definitely a better build quality and plastic. The others began to leak at the seam under pressure after a few years. Nothing catastrophic, but I check under the hood regularly. I can tell this one is much better quality. I've used FCPEuro for various Audi parts for years. Great place for parts. They offer a Lifetime Warranty on everything, even oil and filters. You can order new oil and a filter and ship back the old for a refund. You can ship back old brake pads for a refund as well. No joke. I've never done that, but it's great piece of mind for all other parts.

 

That's great to hear. Yes I love that about FCP Euro. I've never done it but it's a great option if this coolant tank ever fails or leaks. I guess I got pretty lucky choosing this tank. When I need brakes I will probably order from them.

 

Remember ditching plastic altogether is also an option if you have issues with it in the future: https://carrs4x4.com/products/land-r...tank-reservoir

 

You took a lot of steps. I just dump old fluid flush system and get rid of that plastic tank. You will be doing it again soon.

first time I seen fluid clamps. Watch for damage on these old hoses. They crack easy

 

Well crafted writeup !

 

Thanks for the write up. My tank is working fine at this point but is more opaque and difficult to see the fluid level. I may change to this one just for the better visibility. The Carr tank looks awesome but don’t think I can justify the expense right now. That’s as much as I paid for a new Nissans radiator and in-line thermostat combined, though it is tempting…

 

All good and clean. However, we live in the 21st century and there is no need to push green IAT coolant that is terrible for pets, wildlife, and the environment. There are many better and safer choices out there. My journey across the country suggests that common stores (AutoZone, Advanced Auto Parts, NAPA, Wal-Mart, etc.) and dealership carry more than enough non-green stuff so that you can easily find a match if you're in a pinch.