Radiator - removal, inspection and refitting

Cooling, heating and air conditioning systems / Radiator - removal, inspection and refitting

Removal
1 Disconnect the battery negative lead.

2 Drain the cooling system.

3 Disconnect the wiring from the thermoswitch and cooling fan motor (see illustrations).

3.3a Radiator thermo-switch - 1.8 litre

3.3b Detach cooling fan lead connector

4 Disconnect the top hose and expansion tank hose from the radiator (see illustration).

3.4 Radiator securing bolt (A) expansion ank hose connection (B) and top hose connection (C)

5 Undo the two retaining bolts (see illustration) and remove the insulators and L brackets from the top of the radiator. Note that the longer bracket is the centre one.

3.5 Radiator central retaining bolt and bracket

6 Remove the front grille.

7 Remove the two bolts each side at the front and remove the left and right-hand air ducts.

8 The radiator can now be lifted from the engine compartment whilst taking care not to damage the matrix (see illustration).

3.8 Lifting out radiator and cooling fan assembly

Inspection
9 Remove the screws and withdraw the cowling and fan from the radiator.

10 Clean the radiator matrix of flies and small leaves with a soft brush or by hosing. At the same time check for signs of damage and coolant leakage.

11 It is not possible to repair this type of radiator without special equipment.

12 Renew any hoses or clips that are damaged.

Refitting
13 Refitting is a reversal of removal. If necessary, renew the radiator lower mounting rubbers (see illustration).

3.13 Radiator lower mounting rubber

14 Refill the cooling system.

15 When reconnecting the cooling fan motor wiring, secure the lead to the cowling web (see illustration).

3.15 Secure fan lead with plastic clip (arrowed)