Radiator Installation Guide

WARNING: Never attempt to change the radiator whilst the cooling system is hot or pressurised, as this could result in serious injury.

It is vital that you do not mix radiator coolants. Otherwise a dangerous chemical cocktail will occur which could destroy your new radiator through internal corrosion.

(If your vehicle is still within the manufacturer’s warranty period, we advise that you should use the manufacturer’s recommended coolant to avoid any future claim being declined in the event of a cooling system failure).

1. Take care not to damage the new radiator during the installation procedure.
2. Before flushing the cooling system conduct a thorough inspection of all components including hoses, clamps, water pump, thermostat housing and pressure cap. If there are signs of leaking, or the hoses are cracked, swollen or spongy, then they should be replaced at this time.
3. Before removing the old radiator, thoroughly flush the entire cooling system with a reliable radiator flush product. Failure to do so may leave harmful contaminants in the system which could lead to blockage of the new radiator or even cause it to fail prematurely.
4. Add the flushing fluid to the cooling system and run the engine for 15 minutes (with the heater switch turned fully on).
5. Drain the cooling system completely (including the overflow reservoir), then flush again using fresh water, ensuring to collect all the fluid for correct environmental disposal. (The drain plug is located at the bottom of the radiator tank, and it helps to have the pressure cap removed when you do this).
6. Release the bottom hose clamp. If the hose will not come loose by hand, use a long handled screwdriver to break the seal between the hose and the radiator connection. Drain any remaining fluid from the cooling system. Use the same procedure for the top hose.
7. If your vehicle has an automatic transmission, the transmission oil lines will need to be removed from the bottom tank of the radiator. Carefully remove the couplings without bending the oil pipes. It is adviseable to secure the lines upwards to avoid oil loss.
8. If your vehicle has an engine driven fan, disconnect the fan shroud and fan sensor from the radiator. If your vehicle has electric fans, these should be disconnected from the wiring relay, and remove still attached to the radiator.
9. Locate and release the radiator mounts. These are normally located on the ends of the top radiator tank, or if it is a crossflow radiator, on the sides of the radiator.
10. Lift the radiator from the engine compartment.
11. At this point we recommend inspection of the thermostat for signs of wear or sticking, and if evident, the thermostat should be replaced. A faulty thermostat could jam in the closed position, and as well as blowing out the new radiator, could cause serious damage to your engine.
12. Compare the new radiator to the old one to ensure correct selection. Remove fans and any other fittings (such as sensors, mounting rubbers, clips etc) from the old radiator and transfer to the new radiator. If hoses or clips appear worn, they should be replaced.
13. Install the new radiator using the reverse of the above instructions. Once all fittings have been tightened, fill the system with either demineralised, distilled or rainwater, and add the vehicle manufacturer's recommended coolant.
14. Leave the radiator cap off and let the engine idle for approx. 15 minutes to ensure that the fans are working and that the thermostat is operating correctly and allowing the coolant to flow. Re-inspect the cooling system including under the vehicle, for any leaks. Examine the rubber seal underneath the radiator cap and replace cap if the seal is cracked or swollen.
15. Check for air locks, and bleed the system via the designated bleed points if necessary. If your vehicle has bleed points, ensure that they are open whilst filling the cooling system. You should refer to your owner’s manual to confirm if your vehicle has these and needs to be purged.
16. Monitor the temperature gauge for the next few days to ensure that it is operating within the normal range for the vehicle. After the vehicle has been driven, and when the cooling system is cold, recheck the coolant level and top up if required (we recommend doing this the next day). If your vehicle’s radiator does not have a pressure release cap, the coolant needs to be added through the overflow reservoir.

Remember: Never open your radiator cap until the system is cool, and never open it whilst the car is overheating.

If you are unsure about installing the radiator yourself, please refer to your regular mechanic, or call us on 1300 2 B COOL for free advice.

Manufacturers will not warrant their radiators against internal or external corrosion.