Radiator: Service and Repair
RADIATOR BLOCKDisconnect the vehicle battery. Open the bonnet and fit wing protection. Release and remove the header tank and engine pressure caps. Undo and remove the system bleed tap from the left-hand side of the radiator top rail. Raise and support the front of the vehicle. Place a drain tin in position below the radiator bottom hose. Slacken the hose securing clip and withdraw the hose from the radiator.
Allow the coolant to drain into the tin.
From beneath; undo and remove the fan cowl lower securing nuts. From above; displace the relay base from the top panel mounting bracket (1 Fig. 1). Undo and remove the fan cowl to radiator top panel securing nuts (2 Fig 1), reposition the earth leads. Displace the harness retaining clips, reposition the fan cowl from the top panel. Remove the "P" clips securing the radiator bleed pipe to the top panel.
Release and displace the air conditioning drier unit (1 Fig. 2) from the top panel. Slacken the securing clips and remove the radiator bleed pipe hoses from the thermostat housing and header tank. Undo and remove the bleed pipe to radiator banjo bolt, remove the bolt and sealing washers (2 Fig. 2).
Undo and remove the air conditioning conditioning top panel securing nuts (3 Fig. 2). Undo and remove the top panel to body securing bolts (4 Fig. 2), reposition earth leads. Cut harness to panel ratchet straps, displace panel from position and carefully lay on top of engine. Slacken securing clips and disconnect top hoses from radiator. Slacken clip and disconnect radiator to header tank hose from header tank.
Position suitable container catch possible residue and undo and remove the transmission cooler pipes from the right-hand side of the radiator.
Blank open ends of oil cooler pipes.
Displace the radiator from the lower mountings and remove from the vehicle, place aside.
Slacken the clip and remove the header tank hose from the radiator.
Carefully cut and remove the foam padding.
Apply adhesive to the foam padding and position and attach to the replacement radiator.
Fit and secure the radiator heater tank hose to the radiator.
Lubricate lower mounting studs, position and seat the radiator to the vehicle, engaging the lower mounting rubbers and routing the hose to the header tank.
Remove the oil cooler pipe blanking plugs and radiator blanks.
Discard the sealing rings, clean unions and fit new sealing rings. Fit pipes to the radiator and tighten to secure. Connect the hose to the header tank and tighten securing clip. Connect the top hoses to the radiator and tighten securing clips.
Connect the radiator bleed pipe hose to the thermostat housing and tighten the securing clip.
Reposition top panel to radiator/condenser mounting studs. Reposition the earth leads and fit and tighten the top panel outer securing bolts.
Fit and tighten the conditioning top panel mounting nuts.
Reposition the drier unit mounting brackets, reposition the bleed pipe 'P' clips and tighten securing nuts and bolts. Reposition fan cowl to upper mounting studs, position harness retaining clips and earth leads and fit and tighten securing nuts.
Fit the bleed pipe to radiator banjo bolt with new copper sealing washers and tighten to secure. Seat the relay to mounting bracket. Reposition harness and secure with ratchet straps.
From beneath; reposition the fan cowl to lower mounting and fit and tighten securing nuts.
Connect the bottom hose to the radiator and tighten securing clip. Lower the vehicle.
Slowly fill the system with the correct concentration of coolant solution through the engine filler cap, allowing the air to bleed through the bleed tap until the header tank is full. Refit the engine and header tank pressure caps. Reconnect the vehicle battery. Set the air conditioning controls to Defrost and 85. Run the engine for approximately 3 minutes at 1000 rpm. Switch the engine off. Open the bleed tap. When all the air has been purged from the system, close the bleed tap. Carefully release and remove the pressure filler cap and top up to the correct level. Check and top up the transmission oil level.
Remove wing protection and close the bonnet.
TORQUE FIGURES
Condenser bracket to top rail 8 - 1ONm
Oil cooler pipes 54 - 60Nm
Fan cowl to body 8 _ 10Nm
Fan mounting to cow/8 - 10Nm
Fan cowl to mounting bracket 8 - 10Nm
Hose clip 2.5 - 3.5Nm