Radiator rant

[Longtallsally]

Do I seriously need to remove half the damn vehicle just to replace the radiator?

I started the drain process and was getting ready to flush (I put it in the garage so it could be a little warmer for the process) and then started poking around after getting the thermostat out to get an idea of how much effort would be associated with it.

It started to look a little stupid, so I went ahead to the manual (the shorter version, not the full on RAVE) and you might as well remove the engine FFS. Grille, both oil coolers, fan, even the flippin horns! Compounding this is the fact that the motor was replaced, so half the fasteners are not standard and although all there, are all different. I saw a thread on some Aussie Rover forum where the guy even removed the bumper?!?!?!!?!

I know I'm a noob, but this ain't my first rodeo on something (that should be) as simple as a radiator replacement and with all the well documented cooling issues these things have, this is really dumb. I'm really just pissed because now the truck will be down for that much longer while I carve out time to finish this. I've not even started to address the 3 amigos. Oh well, I still love the truck but always get annoyed when I see unnecessary complexity to a simple system.

/rant

 

[Tugela]

I still love the truck but always get annoyed when I see unnecessary complexity to a simple system.

In a sentence you have neatly summarized D2 ownership. This will not be the last time you feel this way about it. On a brighter note, it's now legal to import 200 TDI Discoveries and Defenders, although these are not without their own frustrations.

 

[Maximumwarp]

You can leave the coolers and fan in place. Grille does have to come out, but that's fairly easy.

 

[Longtallsally]

In a sentence you have neatly summarized D2 ownership. This will not be the last time you feel this way about it. On a brighter note, it's now legal to import 200 TDI Discoveries and Defenders, although these are not without their own frustrations.

We already brought back a 460 series 300GD from when we lived in Europe, so I don't need another machine like that. But yeah, I'm starting to learn that Nigel may have been pissed when some of the coordination of components was put together...

You can leave the coolers and fan in place. Grille does have to come out, but that's fairly easy.

I assuming then that the coolers can be disconnected from the radiator once I get the grill off and have access to the horn brackets? Also, isn't the condenser in the way?

 

[Maximumwarp]

I assuming then that the coolers can be disconnected from the radiator once I get the grill off and have access to the horn brackets? Also, isn't the condenser in the way?

Yes, there is a screw on one side that, when removed, allows you to slip the cooler out of a little bracket on the opposite side. You'll see what I mean. I also don't remember having to do anything with the horns...condenser wasn't an issue either.

 

[Longtallsally]

After studying the diagrams a bit I see what you mean. Shouldn't be as big of a PITA as I thought.

Thanks for talking me down.

The REAL reason I'm annoyed is that I want to enjoy driving it and getting all the little stuff sorted. Until I get this finished I can't even drive it without fear of doing damage, so I'm just being impatient. And although I love the snow, the only advantage to living in CA is that I could work on things year round and not care about the weather.

 

[Tugela]

And although I love the snow, the only advantage to living in CA is that I could work on things year round and not care about the weather.

I have a number of projects for my truck on hold (including radiator replacement) owing to the weather and my lack of a heated, enclosed work space. Forecast temps are below freezing all this week in Seattle. I'm happy to wait, the Cascades are getting tons of snow.

 

[p m]

Radiator replacement on a D1 is a piece of cake, Nick.

 

[Tugela]

Radiator replacement on a D1 is a piece of cake, Nick.

This will be my second go-round and the first swap (on my last truck) went pretty smoothly. I'm just waiting for it to both warm up and stop raining. So maybe by July.

 

[Shiftonthefly1]

I thought the same when I did my first D2 radiator. I took the horns off. I was replacing the coolers and lines so took those off too. There is a few over complicated dumb things on the D2. For the most part its an easy truck to work on. But try to do a starter on a Northstar? It's in the intake Valley. Minimum 15rs book time. Radiator on a early 2000's Taurus? Gotta pull it from underneath. Total night mare. Alternator on a Lumina 3.4 DOHC...gotta take the axle out. Evaporator on a Daimler Chrysler Era product...good God. Could be much much worse. Stupid I agree. But could be way worse.

 

[AbnMike]

Radiator replacement on a D1 is a piece of cake, Nick.

Other than the ridiculous fact that there isn't a drain plug on the D1 radiator, which means you have to wrestle with removing a hose (esp if cold) and ending up with coolant all over you, the ground, etc.

 

[Longtallsally]

I thought the same when I did my first D2 radiator. I took the horns off. I was replacing the coolers and lines so took those off too. There is a few over complicated dumb things on the D2. For the most part its an easy truck to work on. But try to do a starter on a Northstar? It's in the intake Valley. Minimum 15rs book time. Radiator on a early 2000's Taurus? Gotta pull it from underneath. Total night mare. Alternator on a Lumina 3.4 DOHC...gotta take the axle out. Evaporator on a Daimler Chrysler Era product...good God. Could be much much worse. Stupid I agree. But could be way worse.

And here is the voice I needed to hear. I could always be worse.

Here's the part I love so far as I working on getting the grille removed, which requires the turn signal removed, which requires the plastic trim to be removed: You go through the "provided small access hole in the splash guard of the wheel well". I laughed at that one. Still haven't pulled it out yet as I'm wondering if the tire will be in the way, but it's just funny to me that you have to go to 3 different section of the manual to get to the core job to be done.

To be fair, I actually like the structure and organization for the most part of the manual. It does make sense. The repairs are annoying, but it makes sense. Much better than the G Wagen.

 

[p m]

Other than the ridiculous fact that there isn't a drain plug on the D1 radiator, which means you have to wrestle with removing a hose (esp if cold) and ending up with coolant all over you, the ground, etc.

No you don't.
You siphon the coolant from the radiator and the block via the top plug hole.
In the last five years, I replaced four radiators on my trucks without spilling more than a cup. Oil cooler lines result in more mess than coolant.

 

[JohnB]

Oh heck on some cars these days you have to remove almost the entire front clip to replace a headlight bulb.

 

[Shiftonthefly1]

Oh heck on some cars these days you have to remove almost the entire front clip to replace a headlight bulb.

So true. I remember having to charge a couple hundred in my shop on a Prius. You have to do just that. Bumper cover has to come off. I think it's 2-3hrs book time. Lol. Insane.

 

[jymmiejamz]

DO NOT DISCONNECT THE OIL COOLER LINES! They almost always will pop off when you are driving once they have been removed.

 

[Longtallsally]

DO NOT DISCONNECT THE OIL COOLER LINES! They almost always will pop off when you are driving once they have been removed.

Thanks. I'm pretty sure the quick disconnects have been removed/replaced but this is good to know nonetheless.

 

[Longtallsally]

OK, I got the radiator out. No cussing (well just at Nigel and his design) no broken parts, no violence, all good. But the amount of fasteners and brackets and finagling required is just silly.

So my rant continues. The dumbest part? The horns have a bunch of sound deadening material in there that has to be peeled back to get the most critical bolts holding the main bracket in there. In order to get to the bolt, I had to pry the horns out (they are fully engulfed in the sound deadening material) and then try very hard not to tear too much of the material. I know that stuff isn't critical, but hate things like that not being OEM. Just dumb.

I was able to get the oil coolers removed (without disconnecting them) with no bending or major stress on any components (and I did misspeak, the original "quick disconnect" connectors are still there) and just found a way to gingerly wiggle them out.

Next task? Getting it all back together. Final task will be to of course flush and refill and then the fun of the bleed process.

Bottom line? Well, I wanted a fun toy and knew I'd be wrenching. This was an exceptional introduction to the idiosyncrasies of Nigel's intrepid design. So I'm very glad I have a good back up vehicle.

 

[Longtallsally]

OK I got the radiator in. But they can take those *&^$%$*%^)*&^ing oil coolers and shove them where the sun doesn't shine.

It's a damn press fit to get them in the slots so the screw will line up. Just. Plain. Stupid.

I still have the stupid jigsaw puzzle of brackets and other BS to put in.

One of the easiest repairs on an automobile made to be complete PITA.

 

[kcabpilot]

I've done it three times now and I know what you're saying, you have valid points, but it gets you nowhere to fuss and rant about it. You just have to accept it and honestly it's kind of a non-issue the second time because you know all of the "secrets". Yes, there are a lot of steps but I have never had to deal with frozen or stripped fasteners, rust or rot. The parts have to come off and go back on in a specific order but once you know how it's really pretty easy.