Radiator: Service and Repair

Removal
1. Open the engine compartment and fit paintwork protection sheets.





2. Disconnect the battery ground cable.
Remove the battery cover.
3. Drain the coolant from the radiator.
4. Depressurize the climate control system. Observe all safety warnings and precautions stated.
5. Release both gas struts, set the engine compartment cover fully forward to the service access position and support with a wooden (or similar) strut - take care not to damage the engine compartment cover or the radiator grille.
6. Remove the twin fan and motor assembly.





7. Disconnect the radiator breather hose.
Release the Quick-Fit hose (radiator to expansion tank) and disconnect the hose from the radiator.





8. Disconnect the transmission oil cooler lower pipe.
Disconnect and reposition the union nut, lower cooler pipe to radiator. Disconnect the pipe. Remove and discard the O-ring seal from the pipe and fit blanking plugs to the pipe and to the union on the radiator.





9. From above the vehicle, disconnect the transmission oil cooler upper pipe.
Disconnect and reposition the union nut, upper cooler pipe to radiator. Disconnect the pipe.
Remove and discard the O-ring seal from the pipe and fit blanking plugs to the pipe and to the union on the radiator.





10. Disconnect the radiator bottom hose.
Slacken the hose retaining clip and reposition the clip along the hose.
Disconnect the hose from the radiator.





11. Disconnect the radiator top hose.
Slacken the hose retaining clip and reposition the clip along the hose.
Disconnect the hose from the radiator.





12. Release the radiator top retaining panel.
Remove the ten bolts, which secure the panel.





13. Disconnect the discharge hose from the condenser.
Remove the bolt, which secures the condenser discharge hose and disconnect the hose.
Remove and discard the O-ring seal from the hose.
Fit blanking plugs to the hose and to the condenser.





14. Disconnect the condenser jump hose from the receiver/drier.
Remove the bolt, which secures the condenser jump hose and disconnect the hose.
Remove and discard the O-ring seal from the hose.
Fit blanking plugs to the hose and to the receiver/drier.





15. Remove the radiator top retaining panel.
Remove the panel.
Remove the radiator top mounting bushes.
16. Disconnect the bonnet switch harness.





17. Remove the radiator.
Remove the radiator assembly.
Clean coolant spillage from the radiator lower carrier panel.





18. Remove the condenser from the radiator.
Remove the two bolts, which secure the condenser to the radiator.
Remove the condenser.
If necessary, remove the jump hose from the condenser.
19. Remove the fan switch.

Installation





1. Fit new foam sealing strips to the radiator top, and bottom faces.
If removed previously, refit the jump hose to the condenser.





2. Fit the condenser to the radiator.
Position the condenser.
Fit the two bolts, which secure the condenser to the radiator.
Fit the upper mounting bushes to the radiator.
3. Reposition the radiator to the vehicle.





4. Connect the jump hose to the receiver/drier.
Remove the blanking plugs from the pipe and from the receiver/drier.
Fit a new O-ring seal to the pipe. Lubricate the seal with A/C compressor oil.
Connect the pipe to the receiver/drier and fit the securing bolt.





5. Connect the discharge hose to the condenser.
Remove the blanking plugs from the pipe and condenser.
Fit a new O-ring seal to the pipe. Lubricate the seal with A/C compressor oil.
Reconnect the pipe to the condenser and fit the securing bolt.





6. Connect the transmission oil cooler upper pipe.
Remove the blanking plugs and fit a new O-ring seal to the pipe. Lubricate the seal with automatic transmission fluid, and reposition the pipe and the union nut to the radiator.
Connect and tighten the union nut.





7. Connect the transmission lower cooler pipe to the radiator.
Remove the blanking plugs and fit a new O-ring seal to the cooler pipe. Lubricate the seal with automatic transmission fluid
Reposition the pipe and the union nut to the radiator. Connect and tighten the union nut.





8. Connect the radiator breather hose (radiator to expansion tank).
Connect the hose to the radiator.





9. Connect the radiator coolant top hose.
Reposition and connect the top hose to the radiator.
Reposition the hose clip.





10. Fit the radiator top securing panel.
Position and align the top securing panel.
Fit the eight securing bolts to the panel.





11. Tighten the ten bolts, which secure the radiator top panel.





12. Connect the radiator coolant bottom hose.
Reposition and connect the bottom hose to the radiator.
Reposition the hose clip.
13. Fit the twin fan and motor assembly.
14. Remove the temporary wooden support strut and reconnect the gas struts to the engine compartment cover.
15. Check the level and replenish the transmission fluid as necessary.
16. Refill the cooling system.
17. Repressurize the climate control system. Observe all safety warnings and precautions stated.
18. Close the engine compartment cover.
19. Connect the battery and fit the battery cover. Reset the clock and the radio.