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Here's the procedure
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Posted by sam96CS [Email] (#852) [Profile/Gallery] (more from sam96CS) on Sat, 9 Oct 2010 05:33:24 Share Post by Email
In Reply to: Re: No doubt about it, time to replace, Paul Broeckx, Sat, 9 Oct 2010 04:29:13
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I'll let someone else advise you about the JB weld. These radiators usually fail around 130,000 - 160,000 miles, and yours is in that range.

Sorry about the length of the procedure writeup. There are a lot of steps, but none are very difficult.

QUASI'S PROCEDURE TO REPLACE RADIATOR (modified)

Run the front wheels up on ramps or jack and support with stands.

Put a drop cloth under the front of the car

Remove the center splash panel. Remove 10 mm nuts, Pull rear of the splash panel toward the front of the car (it will flex) until it disengages, then pull toward the rear until the front metal clips let go of the edge of the air dam. I found it convenient to also remove the passenger side splash panel.

Position a bucket under the radiator drain plug, passenger side, underneath. It needs to hold at least 2 gallons.

Remove the drain plug. No big deal if you break it. It takes a while to drain.

Remove the upper radiator hose and let the coolant drain.

Disconnect the upper expansion tank hose.

Loosen the clamp and disconnect the lower radiator hose.

Clean and inspect clamps that will be re-used.

Remove the 10 mm bolt that secures the radiator to the frame (top center).
Remove the 10 mm bolt that secures the radiator to the intercooler (top center).

For this step, I had to bend the lower radiator hose back and stow out of the way - be careful if your hoses are old (inspect while you're at it; if soft or cracked, replace). I also found it pretty much a necessity to remove the intercooler hose to make some room. From underneath, loosen the two small mount bolts that secure the oil cooler to the radiator (7 mm socket on a 3" extension worked for me - 7/32" socket will work too). No need to remove them, just loosen enough to slide the cooler up.

Remove the 7 mm-headed bolt that secures the oil cooler to the radiator at the top.

Disconnect the two electrical connectors at the fan motor.

Disconnect the BPC from the bracket (if the car has a full pressure turbo).

Wipe clean the two automatic transmission lines where they attach to the old radiator. Disconnect the two auto transmission cooler banjo bolts. Plug or tape the ATF hoses to prevent dust/dirt from entering the transmission.

Pull the oil cooler up as far as possible (it will barely move, thanks to AC hoses). Slide it off the two small mount bolts. Now lift out the radiator with the fan assembly still attached to it.

Prepping the new radiator: Remove the fan assembly - two T-25 screws and a 7 mm bolt - then slide the tab out of its capture point. On my radiator I had to transfer the two Tinnerman nuts and the rubber mount from the old radiator to the new. The thick part of the mount goes forward. The trick to installing the rubber mount is to remove the metal inner sleeve, install the rubber part, then slide the sleeve back inside the rubber. You'll also have to transfer the two 7mm bolts that secure the bottom of the oil cooler to the radiator - run them all the way down, then back them off about 1/16 of an inch to accept the oil cooler. Remove the plastic plugs where the ATF cooling lines attach (do no remove the plugs if the transmission is manual).

Re-installation: Move the oil cooler as far out of the way as possible and install the radiator. Re-engage the oil cooler and install the top bolt. Tighten the two lower bolts that secure the bottom of the oil cooler.

Reconnect everything -
install the two bolts that secure the radiator and intercooler.
top radiator hose - tighten the clamp.
expansion tank hose - tighten the clamp.
reconnect the two electrical connectors to the fan.
reinstall the BPC.(full pressure turbo cars only).
install the lower radiator hose and tighten the clamp.
install the intercooler hose and tighten the clamps.
Top up with a 50-50 mix of premium coolant and distilled water. Fill it to the Max line on the expansion tank.

Start the engine, look for leaks, check everything. Let it warm to normal operating temperature, then check the coolant level again. If you need to add coolant, then wait for the engine to cool!

Check everything. Tighten clamps where it leaks. If boost is less than normal, then re-check the intercooler hose connection. If all is normal then reinstall the splash panel(s).
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