Radiator: Service and Repair
RADIATOR BLOCKCAUTION: Do not remove the pressure cap at the remote header tank unless the engine is cold.
Open the bonnet and fit wing protection. Release and remove the pressure cap. 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. Lower the vehicle.
Remove the ram tube and air cleaner assembly. Slacken the securing clip and remove the top hose from the radiator.
Slacken the bleed hose securing clip at the left-hand side of the radiator and remove the hose. Undo the bleed hose pipe retaining nuts and displace the pipe from the top rail.
Fig 2:
Release the ratchet strap and disconnect the thermostatic switch multi-plug connector. Remove the receiver/drier unit mounting bracket to top rail securing nuts. Displace the unit from the top rail (Fig. 2).
Undo and remove the top rail to body outer securing bolts, reposition the earth leads.
Undo and remove the radiator to top rail securing nuts, remove the rubber mounting bushes. Displace and remove the top rail from the vehicle. On automatic vehicles, place a suitable drain tin in position beneath the transmission oil cooler pipes. Undo the oil cooler pipe union nuts and disconnect the pipes from the radiator.
Allow the oil to drain into the tin.
Discard sealing rings from the pipes and blank open ends.
Fig 3:
Displace the radiator from its lower mountings and carefully lift and remove from the vehicle (Fig. 3).
Fig. 1:
Remove the radiator sealing rubbers and the thermostatic switch (Fig. 1) from the radiator. Fit the thermostatic switch with new seal interposed and the sealing rubbers to the replacement radiator.
Position the replacement radiator to the vehicle, locating the lower mounting points.
Align the upper mountings in the top rail and refit the rubber bushes and securing nuts.
Align the top rail, reposition the earth leads and fit and tighten the outer securing bolts. Tighten the radiator upper mountings. Remove the oil cooler pipe blanking plugs and with new sealing rings, fit and tighten the pipes to the radiator.
Reconnect the thermostatic switch multi-plug connector, secure with ratchet strap. Reposition the receiver / drier unit mounting brackets to the top rail, fit and tighten the securing nuts.
Refit the bleed hose to the radiator and tighten the securing clip.
Reposition and tighten the bleed pipe clip mountings to the top rail.
Refit the top hose and tighten the securing clip. Refit the bottom hose and tighten the securing clip. Refit the ram tube and air cleaner assembly.
Fill the system with the correct concentration of coolant solution.
Never fill the system with water only.
Refit the pressure cap.
Check and top up the automatic transmission fluid level.
Set the air conditioning / heater controls to full heat. Run the engine until correct operating temperature is reached, i.e. the thermostat is open and check for leaks.
Stop the engine and when cool carefully release the pressure cap.
Remove the cap and top up to the correct level. Recheck the automatic transmission fluid level. Refit the pressure cap and close the bonnet.
TORQUE FIGURES
Hose Clips 2.5 - 3.5Nm
Receiver dryer bolts 23 - 27Nm
Top rail to body 23 - 27Nm