Joined
·
48 Posts
After several months of getting ready, over the past week changed out the maybe-original weepy radiator for a new C&R purchased from a forum member here. (Once we started, it was obvious someone else had been there before us...doing something).
While before beginning there was intention to document it all with photos, really the few posted here tell the whole story as much as it can be with pictures. Only words heavily peppered with a really old man's expletives can describe the fittings, nuts, bolts, and threaded inserts that had corroded far beyond any hope of easy removal.
That plus there are a few places, (plenum, fog lamps, and grill), where gaining access with any wrench or driver was...typical enough, even when they weren't all frozen together in rust. Now getting the valance, fog lamps, and underpans back together will be a necessary lesson in innovation. (Not sure now if we needed to remove both bolts holding the fog lamps...but we did).
Do not, do not, even think about doing this without a lift, at least two portable lamps, mini-flashlights, and someone to help.
Altogether, it took two of us 40 labor hours, working very slowly, very diligently, and very patiently, (4 days, 5 hours each). But, we only broke nuts, bolts, and inserts. Except for taking great care to not break anything else and the time it took to do that, the whole thing would have gone pretty quick and simple, which is why there is only a few photos showing the radiator tub dropped down ready for work.
We did not break the connections for the oil coolers, (just very gingerly pushed and twisted them around some). The air conditioning hoses and condensers are obviously designed to facilitate a radiator change, (just about the only thing that was), so no problems with that.
Added grommets to the radiator mountings where it attaches to the tub, as Wayne Ellison recommends. Interesting that the holes in the tub had already been enlarged to about 1/2in dia. so mounting bolts weren't doing much anyway.
Both lower tub mounting brackets were broke entirely where the upper strut meets the lower at the tub, so they were replaced with new from Lotus thru JAE. One of them had to be shipped in from UK. That they are broke after 40K-miles on the car suggests even the new ones are incapable of sustained loading and front end vibration and could be part of the weepy radiator problem. Guess they will last awhile anyway.
If anyone has any ideas about what to do with ripped out insert holes and getting a bolt or screw back into one please let me know...please.
Once the plastic parts are all back together...time to add coolant.
According to PO service records the old coolant was "global," which I think means OAT. The last few days spent some time learning some about coolants, and found other aluminum engine/radiator users have a preference for Zerex G-05.
Called PEAK tech rep to learn more about Last Charge Global, which is OAT, and decided maybe its the best choice, (only available at truckstops and diesel truck suppliers as its intended for big-rigs, although it is a "stocking-option" at WalMart).
Unlike other coolants, PEAK Last Charge technology maintains constant (no loss) suspension of lubricants and corrosion inhibitors and has a lot of each of them. So its better technically and there is no need to change it out before 1-million miles.
When using other coolants, even OAT or HOAT, once the lubricants and corrosion inhibitors start dropping out of suspension there is increasing potential for corrosion and water pump breakdown.
Also, according to PEAK, Last Charge can be used without the need for flushing if switching from non-OAT coolant, (just drain the old stuff out).
Whether G-05 or Last Charge, or any not 50/50 coolant, it MUST be diluted with de-mineralized water and NEVER topped off with anything else, like tap water.
So, going with G-05 if I can't find Last Charge locally...unless someone has a better idea?
CAPTIONS:
Photo 1 - Tub dropped down, old radiator out.
Photo 2 - View from front/left. Note A/C lines and oil coolers.
Photo 3 - View from left side.
Photo 4 - View from underside and behind.
Photo 5 - Beautiful new Ellison/C&R radiator...an engineering marvel. Thank you Wayne, thank you, for all your effort and assistance.
While before beginning there was intention to document it all with photos, really the few posted here tell the whole story as much as it can be with pictures. Only words heavily peppered with a really old man's expletives can describe the fittings, nuts, bolts, and threaded inserts that had corroded far beyond any hope of easy removal.
That plus there are a few places, (plenum, fog lamps, and grill), where gaining access with any wrench or driver was...typical enough, even when they weren't all frozen together in rust. Now getting the valance, fog lamps, and underpans back together will be a necessary lesson in innovation. (Not sure now if we needed to remove both bolts holding the fog lamps...but we did).
Do not, do not, even think about doing this without a lift, at least two portable lamps, mini-flashlights, and someone to help.
Altogether, it took two of us 40 labor hours, working very slowly, very diligently, and very patiently, (4 days, 5 hours each). But, we only broke nuts, bolts, and inserts. Except for taking great care to not break anything else and the time it took to do that, the whole thing would have gone pretty quick and simple, which is why there is only a few photos showing the radiator tub dropped down ready for work.
We did not break the connections for the oil coolers, (just very gingerly pushed and twisted them around some). The air conditioning hoses and condensers are obviously designed to facilitate a radiator change, (just about the only thing that was), so no problems with that.
Added grommets to the radiator mountings where it attaches to the tub, as Wayne Ellison recommends. Interesting that the holes in the tub had already been enlarged to about 1/2in dia. so mounting bolts weren't doing much anyway.
Both lower tub mounting brackets were broke entirely where the upper strut meets the lower at the tub, so they were replaced with new from Lotus thru JAE. One of them had to be shipped in from UK. That they are broke after 40K-miles on the car suggests even the new ones are incapable of sustained loading and front end vibration and could be part of the weepy radiator problem. Guess they will last awhile anyway.
If anyone has any ideas about what to do with ripped out insert holes and getting a bolt or screw back into one please let me know...please.
Once the plastic parts are all back together...time to add coolant.
According to PO service records the old coolant was "global," which I think means OAT. The last few days spent some time learning some about coolants, and found other aluminum engine/radiator users have a preference for Zerex G-05.
Called PEAK tech rep to learn more about Last Charge Global, which is OAT, and decided maybe its the best choice, (only available at truckstops and diesel truck suppliers as its intended for big-rigs, although it is a "stocking-option" at WalMart).
Unlike other coolants, PEAK Last Charge technology maintains constant (no loss) suspension of lubricants and corrosion inhibitors and has a lot of each of them. So its better technically and there is no need to change it out before 1-million miles.
When using other coolants, even OAT or HOAT, once the lubricants and corrosion inhibitors start dropping out of suspension there is increasing potential for corrosion and water pump breakdown.
Also, according to PEAK, Last Charge can be used without the need for flushing if switching from non-OAT coolant, (just drain the old stuff out).
Whether G-05 or Last Charge, or any not 50/50 coolant, it MUST be diluted with de-mineralized water and NEVER topped off with anything else, like tap water.
So, going with G-05 if I can't find Last Charge locally...unless someone has a better idea?
CAPTIONS:
Photo 1 - Tub dropped down, old radiator out.
Photo 2 - View from front/left. Note A/C lines and oil coolers.
Photo 3 - View from left side.
Photo 4 - View from underside and behind.
Photo 5 - Beautiful new Ellison/C&R radiator...an engineering marvel. Thank you Wayne, thank you, for all your effort and assistance.
Attachments
-
91.9 KB Views: 601
-
92.4 KB Views: 606
-
104.6 KB Views: 588
-
103.3 KB Views: 565
-
119.3 KB Views: 576