Difference between revisions of "Replace the radiator & cooling fans"

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'''4. Release the tie wraps, and unplug the rad. fan harness connector(s)'''
 
'''4. Release the tie wraps, and unplug the rad. fan harness connector(s)'''
  
−
The procedure documented in the Lotus service notes describes removing the mounting panel to replace the radiator.  I did not find this necessary and was able to remove the radiator with the mounting panel in place.
+
'''5. Release the single fixing at the bottom of each side extension securing the mounting panel to the bottom flange of the crash structure'''
  
−
'''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 aswell''
 
*Step not taken.
 
*Step not taken.
  
Line 25: Line 25:
  
 
'''7. Release the four fixings securing the radiator to the mounting panel, and withdraw the panel from the radiator'''
 
'''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.
 
<gallery>
 
<gallery>
−
Image: replace the radiator step 7a.jpg|One of the brackets holding the radiator to the mounting panel
+
Image: replace the radiator step 7a.jpg|One of the rear brackets holding the radiator to the mounting panel
 
Image: replace the radiator step 7b.jpg|10mm spanner for this job
 
Image: replace the radiator step 7b.jpg|10mm spanner for this job
 +
Image: replace the radiator step 7c.jpg|The front brackets are secured to the mounting panel here
 
</gallery>
 
</gallery>
−
*The mounting panel can be left in place and the radiator withdrawn instead.  This way makes the removal of the complete wireing harness unnecessary.
 
  
 
'''8. Withdraw the radiator and colling 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'''
 
'''8. Withdraw the radiator and colling 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'''
Line 35: Line 36:
 
Image: replace the radiator step 8a.jpg|Car void of radiator!
 
Image: replace the radiator step 8a.jpg|Car void of radiator!
 
</gallery>
 
</gallery>
−
*So as above, the radiator can be removed with the fans still attached.
+
*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 rivetted to the radiator frame.  Withdraw the fan harness through the mounting panel grommet'''
 
'''9. Release the fan motor from the radiator by removing the four nuts securing the fan shroud to the mounting brackets rivetted 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.
 
<gallery>
 
<gallery>
 
Image: replace the radiator step 9a.jpg|Underside of radiator with fan tray attached
 
Image: replace the radiator step 9a.jpg|Underside of radiator with fan tray attached
−
Image: replace the radiator step 9b.jpg|New [http://www.eliseparts.com Eliseparts] hi-pressure radiator with aluminium side tanks
 
−
Image: replace the radiator step 9c.jpg|The new radiator has to be drilled to attach the fan tray and moutning assembly
 
−
Image: replace the radiator step 9d.jpg|New radiator sitting on top of the old OEM rad for aligning the holes needed whilt drilling
 
 
</gallery>
 
</gallery>
−
*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.
 
  
 
'''10. Remove the four screws securing the radiator to the mounting panel'''
 
'''10. Remove the four screws securing the radiator to the mounting panel'''
−
<gallery>
+
*Step not taken!
−
Image: replace the radiator
 
−
</gallery>
 
  
 
'''11. Refit the radiator in reverse order to removal and [[Replace the coolant|refill with coolant and bleed]]'''
 
'''11. Refit the radiator in reverse order to removal and [[Replace the coolant|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 [http://www.eliseparts.com 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 are there is allotment for some play in the mounting points on the panel.
 +
 
<gallery>
 
<gallery>
−
Image: replace the radiator  
+
Image: replace the radiator step 9b.jpg|New [http://www.eliseparts.com Eliseparts] hi-pressure radiator with insufficient securing holes
 +
Image: replace the radiator step 9c.jpg|The new radiator has to be drilled to attach the mounting brackets and fan tray assembly
 +
Image: replace the radiator step 9d.jpg|New radiator sitting on top of the old OEM rad for aligning the holes needed whilst drilling
 
</gallery>
 
</gallery>
−
 
  
 
[[Category:Engine Cooling]]
 
[[Category:Engine Cooling]]
 
[[Category:DIY]]
 
[[Category:DIY]]

Revision as of 22:48, 3 September 2006

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).

1. Remove the front clamshell

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 aswell

  • 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 colling 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 rivetted 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 are there is allotment for some play in the 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

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