Quote:

Originally Posted by Doobs too On an FAQ:-

 

NB Right and left referenced as if sat in the car (opposite to looking in the bonnet)

1/ Remove two air ducts from right hand intercooler

2/ Loosen bottom radiator hose and drain the coolant.

3/ Disconnect all hoses from radiator (two large, one small)

4/ Under the fan shroud is a flap which can be undone so the shroud clears the fan when you pull it out, loosen this (three snap type fixings)

5/ Loosen two top radiator straps and spin out of the way.

6/ Lift out radiator. :Quote

 

 

I'm using the above FAQ to change my radiator but am having some difficulty! :headvswal

 

My Zed is a Jap import N/A Manual and I've disconnected the top hose, removed the top radiator brackets, removed three of the four shroud retaining screws but:-

1) I can't reach the bottom hose to disconnect it nor the fourth shroud screw

2) I can't find the flap under the fan shroud which should enable the shroud to clear the fan

3) I have the Zed on my drive......must it be jacked up in order to access these items?

 

Some detailed info would be welcome as it's going to rain soon :cry:

 

Cheers - Dave

yeah you will need to get underneath mate. remove the undertray and you will see the bottom bolt of the shroud. If i remeber right this bolt attaches to the metal bottom hose properupper thing which needs to come if you want to remove the rad. You will also be able to detach the bottom part of the shroud from underneath which just unclips. You can also more easily remove the rad bottom hose from underneath and also catch the water. I would say removing the rad is 50% working from the top and 50% from the bottom.

 

PS you can also remove the viscous fan easily (5 bolts i think) to give you a bit more room but watch your nuckles scraping on the rad fins when freeing a stuck bolt!!

yeah you will need to get underneath mate. remove the undertray and you will see the bottom bolt of the shroud. If i remeber right this bolt attaches to the metal bottom hose properupper thing which needs to come if you want to remove the rad. You will also be able to detach the bottom part of the shroud from underneath which just unclips. You can also more easily remove the rad bottom hose from underneath and also catch the water. I would say removing the rad is 50% working from the top and 50% from the bottom.

 

PS you can also remove the viscous fan easily (5 bolts i think) to give you a bit more room but watch your nuckles scraping on the rad fins when freeing a stuck bolt!!

 

Thanks for the help.....I'll go and give it a try.

Just got back indoors after a disastrous attempt at replacing my radiator on the drive :headvswal

 

Almost got there but I was unable to jack the car up far enough for me to feel safe underneath and was unable to reach all the screws holding the undertrays.

 

So I've just spent over three hours struggling and straining only to finish up putting the b****y leaking radiator back on.........I am not a chuffed bunny!!!!

 

All I can do now is bring forward my 60k service and get them to put the new rad in when they take the old one out.....I am really pissed off!!!!! If only I had a pit or a carlift it would have been a doddle but, now it's standing on my drive pissing water.

 

Actually, it doesn't leak very much so I am hoping to attend the two SC upcoming meets, Hackpen and IOW, by just topping it up from time to time. Wish me luck.

 

Cheers - Dave

dave when do you need this doing by. as we hope to go down to collect Marcus's Zed on sat can call by and help you do it if you like, i done this before,.

dave forget the jacks bud and get it up on a set of ramps,dont have to be expensive ones. 10mm bolts to undo tray and your there plus you,ll have access to the rad drain plug so you can save your coolant into a bowl,allso better sight of the rad locating rubber bungs at bottom as trying to put in from top is a nose bleed job :( get the ramps and its a breeze mate

Scubie - I'm really choked and thank you very, very much for your kind offer but there are much more deserving souls than me out there for you to spend your valuable time with. I am just suffering the momentory depression we all feel when things go wrong. I'm a lazy sod and just hate spending all that time trying to do a job I should be capable of doing but failing.....I'll get over it. Thanks mate.

 

Znut - Thanks also for your advice and encouragement. I have some ramps buried somewhere in the garage, I'll dig them out and give it another go, maybe tomorrow.

Having retired a few years ago I hate doing work unnecessarily, and to have a go at doing this job twice is going to take a bit of will power....but I'll do it!

 

Thanks for your help, advice and support - Dave

Scubie - I'm really choked and thank you very, very much for your kind offer but there are much more deserving souls than me out there for you to spend your valuable time with. I am just suffering the momentory depression we all feel when things go wrong. I'm a lazy sod and just hate spending all that time trying to do a job I should be capable of doing but failing.....I'll get over it. Thanks mate.

 

Znut - Thanks also for your advice and encouragement. I have some ramps buried somewhere in the garage, I'll dig them out and give it another go, maybe tomorrow.

Having retired a few years ago I hate doing work unnecessarily, and to have a go at doing this job twice is going to take a bit of will power....but I'll do it!

 

Thanks for your help, advice and support - Dave

thats the zed scene dave,theres many jobs on my car ive had to re-do or re-desiegn because it aint worked but remember bud every hour you spend on your zed is £40-50 saved and it gets done to our own standads. turn the frustration into determanation fellow and just get the fvker changed and fixed :)

oh by the way i could re-roof your house blindfolded but i cant spell to save my life :rofl: :rofl: ;)

oh by the way i could re-roof your house blindfolded but i cant spell to save my life :rofl: :rofl: ;)

 

Thank you but my roof doesn't need re-roofing at the moment lol, and your spelling looks fine to me :smash:

real easy bud, no need to remove viscous fan at all!

 

remove radiator brackets x2

If NA you may find it easier to remove both intake feeds to throttle bodies, mark each vaccum feed and pull off breather hoses.

remove radiator cap when cool

remove top hose and small overflow tube (NA)

with car up small amount

remove undertray if present (doubtful)

remove lower u clamp 1 10mm bolt (may not be there)

slacken lower jubilee clip may be the 10mm oem oe might just be an aftermarket flathead screw

collect coolant in tray, move clear of yourself

back up top remove the other end of the hose from the inlet pipe and move out of the way.

unclip lower shround (very easy witha torch look directly at 6 oclock there is a push up clip, simialr to a childrens lunchbox (only way i could describe it lol) pull down with a gentle tug then it will be free

if automatic remove both lines from metal feed pipes, and fit a suitable bolt in each hose so it dont leak atf all over your drive

finally lift up from top of car and it will come out, real easy when you know how

 

not sure what the fook that FAQ you had above about removing intercooler ducts LOL maybe that was about oil cooler for engine who knows!

or drive down mine and il do it!

Thanks Greg - I'm expecting to have another go at it tomorrow so I'll refer to your post. It sounds straight forward........fingers crossed.

 

Cheers - Dave

Scubie - I'm really choked and thank you very, very much for your kind offer but there are much more deserving souls than me out there for you to spend your valuable time with. I am just suffering the momentory depression we all feel when things go wrong. I'm a lazy sod and just hate spending all that time trying to do a job I should be capable of doing but failing.....I'll get over it. Thanks mate.

 

Znut - Thanks also for your advice and encouragement. I have some ramps buried somewhere in the garage, I'll dig them out and give it another go, maybe tomorrow.

Having retired a few years ago I hate doing work unnecessarily, and to have a go at doing this job twice is going to take a bit of will power....but I'll do it!

 

Thanks for your help, advice and support - Dave

 

I ventured out into the wilds of Wiltshire (my front drive) this morning to sus out my rad replacement..............Begger.... the ramps foul the front bumper so back to square one. :mad: :headvswal

can you make the gradient a bit more gentle using extra planks of wood and bricks and stuff?

 

If you dont have it done by friday i can try and lend a helping hand when i come and pick up that wheel you said you would very kindly lend me. However, you do really need a safe way of raising the car so you can work underneath. I have some axel stands you can use but unfortunately wont have them with me on friday but coul bring them up the following week when i am off from work.

can you make the gradient a bit more gentle using extra planks of wood and bricks and stuff?

 

If you dont have it done by friday i can try and lend a helping hand when i come and pick up that wheel you said you would very kindly lend me. However, you do really need a safe way of raising the car so you can work underneath. I have some axel stands you can use but unfortunately wont have them with me on friday but coul bring them up the following week when i am off from work.

 

Yeah.......what I really need is two short planks about as thick as me :headvswal

 

A good suggestion Giant Slayer, I'll follow it up when (if) this rain ever stops!

 

(See your thread about wheel)

 

Cheers - Dave

you dont need to get underneath at all.

 

just reach down the side of the shroud and feel the clip.

 

pull the very bottom part out towards the engine and once it comes loose push it down.dont remove the little bolts from the shroud as this is unnecessary.

 

best thing to do is ring me when your with the car 07706586022

 

Paul

getting the old one out is easy, sqeezing a koyo in is a bit more fun.

getting the old one out is easy, sqeezing a koyo in is a bit more fun.

 

Thank goodness I am using a standard replacement, not the koyo. I've got an N/A so don't think a koyo is needed.

 

Paul, it sounds easy when you write it but I had great difficulty getting my arm down the side of the rad yesterday when undoing the rad drain plug......I'm not sure I would be able to access the shroud as you describe....and what about releasing the bottom hose? I definately can't reach that from above!

Thank goodness I am using a standard replacement, not the koyo. I've got an N/A so don't think a koyo is needed.

 

Paul, it sounds easy when you write it but I had great difficulty getting my arm down the side of the rad yesterday when undoing the rad drain plug......I'm not sure I would be able to access the shroud as you describe....and what about releasing the bottom hose? I definately can't reach that from above!

 

you can leave the hose on at the bottom and leave the radiator full of water, bit tricky getting it past the viscous fan but not that bad, you could get at lower shroud from top, try putting it back on though!

 

greg

Dave,

 

I hope you managed to get this done. I should have made it clear in the FAQ, the car was on ramps when I did this so access was pretty easy. I made the ramps myself as standard ones are too steep, just a plank cut into three unequal lengths and glued together so that the longest is at the bottom and the shortest at the top. Make sure the total height of the ramp is less then the ground clearance of your car so if you drive off the front of them you'll do no damage.

Thank goodness I am using a standard replacement, not the koyo. I've got an N/A so don't think a koyo is needed.

 

Paul, it sounds easy when you write it but I had great difficulty getting my arm down the side of the rad yesterday when undoing the rad drain plug......I'm not sure I would be able to access the shroud as you describe....and what about releasing the bottom hose? I definately can't reach that from above!

 

 

if you can get to the drain you can easily get to the bottom of the shroud.

 

dont take the hose off the bottom they both come off at the top the the lower hose drops down and comes around the fan when you lift the rad out !

Well! Following the advice I've received from you guys, I've managed to remove my leaking radiator. :dance:

 

I made some ramps up with a more gradual gradient (lol) and got the Zed up high enough for me to get underneath without being cramped. The bottom panel came off easily giving unhindered access to the underside of the rad. (None of the 10mm bolts were rusted in!)

 

I loosened the drain plug, released the bottom hose and removed the bottom section of the shroud. I then removed the two rad top brackets, released the top hose and OUT SHE CAME, easy peasy. :smash:

 

I've transferred the shroud and bottom hose retaining bracket to the new rad and now it just remains for me to refit everything in the morning. (It's too dark to finish it tonight)

 

As a matter of interest the front of the rad was almost totally clogged with dead leaves and other debris trapped between it and the grill in front of it. The cooling efficiency of the rad MUST have been severely hampered by all this junk.

 

I thank everyone on this thread who have given lots of advice and encouragement without which I would certainly NOT have been able to complete this task. I particularly want to thank giant slayer and scubie who both offered to come and help me do the job if I couldn't manage it myself. But by following the advice given, a job which seemed beyond my ability has turned into a straight forward, no complications, success and I would recommend it as a simple DIY task for any owner with a molecule of ability.

 

One last question....how critical is the foam rubber that surrounds and seals the rad as most of it is rotten and falling to pieces?

 

Cheers everyone - Dave

Well! Following the advice I've received from you guys, I've managed to remove my leaking radiator. :dance:

 

I made some ramps up with a more gradual gradient (lol) and got the Zed up high enough for me to get underneath without being cramped. The bottom panel came off easily giving unhindered access to the underside of the rad. (None of the 10mm bolts were rusted in!)

 

I loosened the drain plug, released the bottom hose and removed the bottom section of the shroud. I then removed the two rad top brackets, released the top hose and OUT SHE CAME, easy peasy. :smash:

 

I've transferred the shroud and bottom hose retaining bracket to the new rad and now it just remains for me to refit everything in the morning. (It's too dark to finish it tonight)

 

As a matter of interest the front of the rad was almost totally clogged with dead leaves and other debris trapped between it and the grill in front of it. The cooling efficiency of the rad MUST have been severely hampered by all this junk.

 

I thank everyone on this thread who have given lots of advice and encouragement without which I would certainly NOT have been able to complete this task. I particularly want to thank giant slayer and scubie who both offered to come and help me do the job if I couldn't manage it myself. But by following the advice given, a job which seemed beyond my ability has turned into a straight forward, no complications, success and I would recommend it as a simple DIY task for any owner with a molecule of ability.

 

One last question....how critical is the foam rubber that surrounds and seals the rad as most of it is rotten and falling to pieces?

 

Cheers everyone - Dave

Just chuck it in the bin Dave.Oh and well done now you can tackle your next job,with a little help from here if needed.

nice one bud, best way to learn is to be in the deep end and get stuck in, surprisinh how simple some things are once you do them once

no one gonna warn him of the joy of airlocks?