Replace the radiator & cooling fans
The aluminium cored radiator is positioned horizontally on top of the composite 'crash structure' in the front service compartment. A composite moulding is used to mount the radiator, and also, via extensions at each side, to provide a mounting point for the inside front of the clamshell wheelarch. The radiator must be removed for access to the cooling fan(s).
2. Drain the coolant and disconnect the feed and return hoses from the radiator
- You don't need to drain the whole cooling system, better to just undo the inlet and outlet hoses and catch the coolant in a bucket.
Looking down onto the inlet pipe where bleed screw is located (MY04 Elise!)
3. Release the two fixings securing each water shield to the top rear edge of the radiator mounting panel, and withdraw both shields
This photo shows the water shield removed
4. Release the tie wraps, and unplug the rad. fan harness connector(s)
5. Release the single fixing at the bottom of each side extension securing the mounting panel to the bottom flange of the crash structure
NOTE: The procedure documented in the Lotus service notes describes removing the mounting panel to replace the radiator. This it not necessary and it is possible to remove the radiator with the mounting panel in place. This avoid having to remove the front harness wire as well
- Step not taken.
6. Release the three fixings securing the back edge of the mounting panel to the vertical flange on the crash structure, and three fixings along the front edge of the panel
- Step not taken.
7. Release the four fixings securing the radiator to the mounting panel, and withdraw the panel from the radiator
- There are four 's' shaped brackets that hold the radiator in place.
One of the rear brackets holding the radiator to the mounting panel
10mm spanner for this job
The front brackets are secured to the mounting panel here
8. Withdraw the radiator and cooling fan assembly. On AC cars, lift the radiator/condenser assembly only sufficiently to release the cooling fans or radiator as required, without disconnecting the refrigerant circuit
Car void of radiator!
- The radiator is removed with the fans still attached.
9. Release the fan motor from the radiator by removing the four nuts securing the fan shroud to the mounting brackets riveted to the radiator frame. Withdraw the fan harness through the mounting panel grommet
- Here the fan tray can be seen attached to the underside of the radiator.
- The replacement Eliseparts radiator had to be drilled in order to take the fan tray assemble and mounting brackets.
Underside of radiator with fan tray attached
10. Remove the four screws securing the radiator to the mounting panel
- Step not taken!
11. Refit the radiator in reverse order to removal and refill with coolant and bleed
- The Eliseparts radiator had to be modified to fit the Elise, see below
- Make sure the jubilee clips are tight before fitting the clam back on
- Always verify the radiator is fitted correctly before refitting the front clam
New Radiator Modifications
The Eliseparts hi-pressure radiator comes with only a couple of pre-drilled hole for securing to the mounting panel. Further holes need to be made to take the mounting brackets and fan tray assembly.
The simplest approach was to align the new radiator on top of the old OEM radiator and drill through. The holes do not have to be exact as there is allowable movement in mounting points on the panel.
New Eliseparts hi-pressure radiator with insufficient securing holes
The new radiator has to be drilled to attach the mounting brackets and fan tray assembly
New radiator sitting on top of the old OEM rad for aligning the holes needed whilst drilling
