Removing & replacing a radiator

Part 1. Preparation and safety

Objective

• Safely remove and replace a radiator.

Personal safety

Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:

• Work clothing - such as coveralls and steel-capped footwear
• Eye protection - such as safety glasses and face masks
• Ear protection - such as earmuffs and earplugs
• Hand protection - such as rubber gloves and barrier cream
• Respiratory equipment - such as face masks and valved respirators

If you are not certain what is appropriate or required, ask your supervisor.

Safety check

• Coolant in the cooling system could be above its boiling point. Never open a radiator cap fully until ALL pressure has been released.
• When removing a radiator cap, use appropriate gloves, clothes, full face shield, etc.
• Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note

• Make sure the coolant catch tray is large enough to catch any spills and has the capacity to hold all the system coolant.
• If changing coolant, dispose of the old coolant properly in accordance with environmental and legislative requirements.
• If reusing the old fluid, keep it stored in a covered and uncontaminated container.
• Inspect the cooling system hoses and clamps. Replace them if worn or damaged.
• When removing the hoses from the radiator fittings do NOT twist them as this can cause internal damage to the hose and the fitting. If they do not easily release, carefully work a tool between the hose and fitting breaking it loose all the way around. If the hoses are to be replaced, you can slit them with a knife and peel them off the fitting.
• When refitting or replacing hoses, reinstall them all the way on the fittings. Make sure the clamps are installed at the proper place on the fitting, beyond the flared segment, not on top of it.
• Some vehicles have transmission cooler lines attached to the radiator. Remember to disconnect these lines when removing the radiator and always refit before refilling the system with coolant.
• Refill the system with the correct coolant at the proper anti-freeze/water ratio.
• There are a number of different types of coolant, often recognized by colour, as they have different chemical additives that can affect the materials that the engine and system components are made from.
• It is advisable to pressure test the system to check for leaks on completion of the job.
• Start the engine, warm it up until the thermostat has opened and check for proper operation of the cabin heater.
• Check for proper coolant level after it cools sufficiently.

Part 2: Step-by-step instruction

1. Drain the coolant
   Place a drain pan below the radiator and remove the drain plug. Drain the coolant from the system. Replace the drain plug and dispose of the drained coolant in an environmentally approved manner.
2. Remove the radiator
   Carefully remove any hoses that are attached to the radiator. Unscrew any cowlings or covers from the radiator. Remove the bolts or screws that hold the radiator in position in the engine bay, and lift the radiator from its location.
3. Inspect the radiator
   Carry out a visual inspection of the radiator to ensure that it is suitable for reinstallation in the vehicle. If the radiator fins are blocked by debris carefully clean the fins with a dry brush. If the radiator is damaged, advise your supervisor so a decision can be made whether to repair it or replace it.
4. Replace the radiator
   Place the radiator into position and replace the securing bolts or screws. Refit the cowlings or covers. Rotate the fan and belts by hand to check the covers do not restrict movement. Attach the coolant hoses to the radiator,
5. Refill the system
   and refill the system with new coolant of the correct type. Run the engine to circulate the coolant and remove any air trapped in the system. Check that the temperature indicator gauge shows the coolant temperature is in the normal operational range. Top up the radiator or reservoir with coolant if necessary.