DIY Radiator Fix. Advice?
 

Ok all you tech-heads (Or not - it doesnt seem too complicated a procedure - im just cautious) its time to show off.

I seem to have a decent crack in the plastic side-tank bit of my radiator. Pissed out coolant from just behind the top part of the front grille.

Advice? Step by step guide? Send me somewhere? Go nuts...

The crack in the back of the top hot side plastic end tank is a common problem....

DO NOT BUY A SECOND HAND RADIATOR as its 99.99 % likely going to have a crack in the same place or develop one shortly after installation. Been there done that. :mad:

REMOVAL:

1. Disconnect the 2 radiator thermo fans via their bottom clips first.
2. Remove the top 3 RHSide radiator hoses from the radiator that are connected to the header tank.
3. Disconnect the LHS reservoir-bottle-pipe from the top of the radiator.
4. Grab a bucket or find a drain and remove the bottom LHS radiator hose.
5. Undo the 2 top bolts that hold the radiator in place, be sure to bend the power steering cooler pipe ??? out of the way.
6. Lift the radiator carefully straight out.
7. Remove the dozen or so bolts and take off the two thermo fans.

REPAIR:

These guys were the cheapest when I used them.
They do a free pick up, repair and drop off again same day service in the Perth Metro Area.

$220 for replacement of the plastic, hot side end tank, new O-Ring and minor leak repair, plus flush, pressure test and respray of my 99 WRX radiator.

Highly Recommended

[url]www.perth-radiator.com.au[/url]

98 Beechboro Rd
South Bayswater 6053
(08) 9271 7200
FREECALL 1800 676 707

INSTALL:

You can either buy genuine Subaru Coolant if you think you will need the anti-freeze properties it provides or buy Redline Water Wetter for superior thermal cooling properties.

I would also check the condition of the original top and bottom radiator hoses for signs of cracking/splitting as it will be a sure bet they will crack shortly after installing the repaired radiator. Buy silicon items if you want em to last far longer.

The install is basically the reverse of the above procedure.

Re-filling:

1. Fill the LHS radiator reservoir until it will take no more fluid.
2. Start the WRX/STi.
3. Pour fluid slowly in through the radiator header tank. You want bubbles to come up through the fluid while filling. When full - LEAVE THE HEADER TANK CAP OFF!!!!!

4. MOST IMPORTANT PART. BURPING THE WRX. !!!!

- Its important to warm up the engine to remove any air bubbles in the raditor/cooling system so as to prevent any hot spots forming and possibly blowing a gasket/cracking a piston/rings from detonation.

- It takes approximately to 10 minutes to fully warm the engine from cold.
- What your wating for is the two thermo fans to kick in. The cooling system will give a good big air burp up through the header tank removing any lasting air bubbles from highest point in the cooling system. It will overflow slightly.

5. Top up header tank, and radiator fluid reservoir.
6. Do the obvious check for leaks and retighten top and bottom hoses if needed.

7. BEERS, BEERS BEERS with the $100-200 you have saved with the above DIY. In fact invite me over with this last step and I will help ya polish em off!!! ;) ;) ;)

J

MODERATORs PLEASE COPY TO DIY SECTION.

good bit of advice, only thing I'd add is before you start the whole process, make sure your heater is turned on full. If you have been driving before hand, dont get boiling hot radiator fluid all over you