Replacing a Radiator - Gransport

mas

Junior Member
Messages
46
Searching the Forums suggested you need to remove the full front bumper section as a prerequisite for replacing the radiator, but I decided to see if it was possible without removing the bumper. Another known option was to remove the complete radiator assembly with the cowling / air con radiator, but the air con will need disconnecting.

This is what I did with the aim to avoid having to get the air con drainage / recharge.

If you have no patience then pay somebody to do it.

1. Jack up the car with the front wheels removed. Make sure you are using good quality axle stands.

2. From under the car remove the undertray

3. Remove all the engine surround panels (this makes it easier for general access)

4. Remove the air intake pipe/airflow metre (this makes it easier for general access)

5. Remove the front grill

6. Drain the coolant water from the radiator, there is a small plastic nut at the bottom of the radiator.

7. Disconnect the small rubber pipe which is connected to the top of the radiator

8. Remove the top and bottom hoses which connect to the radiator (The top hose, I suggest you mark which end goes into the radiator as it’s useful for reassembling afterwards)

9. From under the car you will see 2 sets of electrical connectors that are fixed/connected onto the chassis cross section. I was not certain how to pull apart the connectors, so I was able to undo the fixing bolts, the objective is to get these wires and brackets out of the way.

10. From under the car remove the 2 wires that connect onto the resistor which is located just over halfway down on the electric fan cowling. Now remove the resistor (it’s secured by 2 small Phillip head screws). If the fixing screws are rusted you can undo them easier after the fan cowling is removed. Worth inspecting the removed resistor to ensure it’s not broken (mine was).

11. The resistor electric cable is secured by 2 push in cable ties running up in the centre of the electric fan cowling, just pull them out firmly, they can be brittle and may even break (I wasted heaps of time on this)

12. From the front of the car disconnect the electrical connections to the 2 electric fans. Now move the wire harness that’s runs on the top of the radiator out of the way by undoing the plastic clips.

13. Time for a cup of tea and a biscuit! (before the frustrating stuff)

14. The big challenge in removing the radiator as the air conditioning pipes and the plastic cowling gets in the way. (You will soon find this out)

15. From underneath the car remove the complete electric fan assembly. There are 4 8mm bolts (one at each corner). The main problem that the electric fan motors foul the chassis cross section. I then removed the radiator securing bolts, this allowed a little more manoeuvring space. Pretty sure at this stage I also tied a wire on the air conditioning radiator (left bottom side – when standing in front of the car) to avoid it dropping down.

16. Optional extra. I also took the opportunity to remove/replace the coolant thermostat which is held within the elbow as a single assembly with 3 allen keys bolting it onto the engine block.

17. At the bottom of the radiator there are 4 or 5 small nut/bolts that secures the cowling, remove these (there is a good chance they are rusty – so replace with stainless steel afterwards)

18. At the top of the radiator again there are 4 or 5 small nut/bolts. Getting access to this is a pain, but you can carefully move the radiator /air con sufficiently to gain access and remove them.

19. Another cup of tea is due.

20. Next, you need to disconnect the 2 power steering rubber pipes that connect onto the power steering narrow radiator. Suggest you have some old bolts so you can plug the rubber pipes to prevent steering fluid coming out.

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21. I found that I still could not pull the radiator out from under the car as the power steering narrow radiator was fouling the cowling. No option but to remove it. It’s held by 3 bolts secured onto the water radiator front edges.

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22. I was then able to remove the water radiator.


Fitting the new radiator, This is the reverse. However a few tips

1. I tried fitting the power steering radiator onto the water radiator first, unfortunately the air con / cowling gets in the way when you try fitting it in.
Instead, Insert the new water radiator having somebody holding it in place, now via the front grill opening insert the power steering radiator and with careful manoeuvring it’s possible to bolt it onto the water radiator.

2. Before you fit the electric fan cowling, fit the top radiator hose first. Also ensure the water radiator is loose as it will make it easier manoeuvring the electric fan cowling into place. Take car not to damage your new water radiator!!

Good luck.
 

BL330

Member
Messages
1,121
Thanks for the post Mas.
I have a new thermostat and housing with 'o' ring to be fitted. I was planning to give it to Fernando my mechanic to do.
What access will he have to get to it, or will he need to take the radiator out? He is quite adept at taking the bumper panel off.
Regards,
Bruce
 

mas

Junior Member
Messages
46
Bruce,

It's straight forward replacing the thermostat and the gasket. The radiator / electric fans do not need taking out. I had done it before on a previous 4200 I had. My only comment that even with the official "o" ring I put a small bead of gasket sealant as I recall it leaked.

Gary
 

conaero

Forum Owner
Messages
34,593
Thanks for that, so it is possible.

I had my front bumper off for respray so hence why I did not explore an alternate method of removal but its good to know it is doable.