Radiator and intercooler -
turbocharged engines
Removal
13 Remove the right-hand headlight lens unit
as described in Chapter 12, Section 7.
14 Remove the air cleaner components, as
necessary for access to the radiator, as
described in the relevant Part of Chapter 4.
15 Drain the cooling system as described in
Chapter 1. Leave the bottom radiator hose
disconnected.
16 Slacken the retaining clip and disconnect
the radiator top hose.
17 Disconnect the cooling fan motor
multiplug(s) at the wiring connector(s).
18 Disconnect the wires at the thermostatic
switch(s) just below the top hose outlet.
19 On pre-1992 model year vehicles, remove
the radiator grille as described in Chapter 11,
Section 19.
20 Undo the two bolts each side securing the
centre platform to the body side members.
21 Undo the nut and retaining bolt securing
the bonnet safety catch to the centre
platform.
22 Lift the centre platform upwards, turn it
over, and cut off the cable ties securing the
bonnet release cable to the platform
underside. Remove the platform from the car.
23 Slacken the hose clip and disconnect the
coolant outlet hose at the turbocharger.
24 Slacken the retaining clip and remove the
air intake hose from the turbocharger.
25 Slacken the two clips and remove the air
intake and outlet hoses from the intercooler.
26 Lift the radiator and intercooler upwards,
and carefully remove the assembly from the car.
27 If required, remove the upper and lower
mounting bolts and nuts and separate the
intercooler from the radiator.
28 With the radiator removed, it can be
inspected for leaks and damage. If it needs
repair, have a radiator specialist or dealer
service department perform the work, as special
techniques are required. Clear the matrix of flies
and small leaves with a soft brush, or by hosing.
29 Reverse-flush the radiator, as described
in Chapter 1. Renew the top and bottom
hoses and clips if they are damaged or have
deteriorated.
Refitting
30 Refitting the radiator and intercooler is a
reversal of removal, but ensure that the lower
mounting lugs engage in the rubber
grommets, and the centre platform grommets
locate over the radiator upper lugs. Re-secure
the bonnet release cable to the centre
platform, using new cable ties. On
completion, fill the cooling system as
described in Chapter 1.
8 Radiator (V6 engines) -
removal, inspection and
refitting
1
Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
Removal
1 Drain the cooling system as described in
Chapter 1. Leave the bottom radiator hose
disconnected.
2 On pre-1992 model year vehicles, remove
the radiator grille as described in Chapter 11,
Section 19.
3 Undo the two bolts each side securing the
centre platform to the body side members
(see illustration 5.6).
4 On vehicles with air conditioning, undo the
two nuts securing the condenser to the front
of the centre platform (see illustration).
5 Undo the nut and retaining bolt securing
the bonnet safety catch to the centre platform
(see illustration 5.7).
6 On vehicles equipped with air conditioning,
cut off the cable ties or undo the screws and
release the support straps, securing the
various hoses to the centre platform and to
the fan cowl (see illustration).
7 Lift the centre platform upwards, turn it
over, and cut off the cable ties securing the
bonnet release cable to the platform
underside. Remove the platform from the car.
8 Slacken the retaining clip and disconnect
the radiator top hose.
9 Disconnect the cooling fan motor
multiplug(s) at the wiring connector(s).
10 Disconnect the wires at the thermostatic
switch(s) just below the top hose outlet.
11 Where applicable, unscrew the union nuts
and disconnect the automatic transmission oil
cooler pipes from the radiator. Cover the
disconnected pipes and fit blanking plugs to
the radiator ports.
12 Lift the radiator upwards, and carefully
remove it from the car.
13 With the radiator removed, it can be
inspected for leaks and damage. If it needs
repair, have a radiator specialist or dealer
service department perform the work, as
special techniques are required. Clear the
matrix of flies and small leaves with a soft
brush, or by hosing.
14 Reverse-flush the radiator, as described
in Chapter 1. Renew the top and bottom
hoses and clips if they are damaged or have
deteriorated.
Refitting
15 Refitting the radiator is a reversal of
removal, but ensure that the lower mounting
lugs engage in the rubber grommets, and the
centre platform grommets locate over the
radiator upper lugs (see illustrations 7.12a and
7.12b). Re-secure the bonnet release cable
and hoses to the centre platform, using new
cable ties. On completion, fill the cooling
system as described in Chapter 1. On models
with automatic transmission, top up the
transmission fluid as described in Chapter 1.
9 Water pump (4-cylinder
engines) -
removal and refitting
4
Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
“M” Series engines
Removal
1 Drain the cooling system as described in
Chapter 1.
2 Remove the timing belt as described in
Chapter 2, Part A.
3 Undo the three remaining bolts securing the
lower backplate to the engine, noting that on
some engines, one bolt also retains a breather
hose clip, and one retains an oil pipe clip.
Remove the lower backplate (see illustration).
Cooling, heating and air conditioning systems 3•7
8.6 Undo the screw and release the hose
support strap from the fan cowl
8.4 Condenser-to-centre platform
retaining nuts (arrowed) on the right-hand
side
9.3 Removing the lower backplate from
the engine (early metal version shown,
later plastic version similar)
3
1380 Rover 800 Series Remake
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