MK19
02-04-2004, 11:00 PM
OK, so ya got the bad ass PWR radiator- AND, ya figured, since you have the radiator out, why not get the Zero/Sports cool thermo... So, parts in hand, let's start. Here's what you'll need:
http://69.13.78.254/albums/1003/Kopf_Jager/PWR.jpg
PWR radiator
Zero/Sports cool thermo w/ gasket
2 gallons radiator coolant (new radiator takes right at 1.5 gallons of coolant)
6 new hose clamps (good time to change them)
high grit sandpaper (1500+) or scratch pads
torque wrench
12mm (your choice, socket is good)
14mm (same as above, your choice)
flathead screwdriver (for hose clamps and fan plugs)
*6 new machine screws (for mounting fans and overflow tank)
funnel with plastic tubing (for filling the radiator)
Catch pan for coolant
OK, so we're ready? Right! First, ensure car has sat for at least 3 hours- coolant retains heat very well. First, begin with removing the coolant overflow tank. Simple, just 2 screws and a hose. Then remove the air intake duct and radiator supports (12 & 14mm). Remove small coolant hoses on the left of the radiator (coolant will spill now - make sure catch pan is positioned). Remove upper radiator hose. Now you can get to the fan plugs. The plugs are removed by pulling up, not down, on the tabs (use flathead). Once plugs are removed, you can probably get to the lower radiator hose and remove it (may require going underneath the car- I didn't have to). Coolant will now really flow, so repositon pan prior to removal. Detatch the power steering line from the support clip on the radiators right side. Allow system to empty. Now the radiator is ready to remove. Best way is to pull up from the top and to the right.
Here we can see the size difference in the bad boy (PWR) and the OEM:
http://69.13.78.254/albums/1003/Kopf_Jager/PWR-vs-OEM.jpg
Now that the radiator is out, time to remove the fans (use 10mm) and the overflow tank line
http://69.13.78.254/albums/1003/Kopf_Jager/OEM-radiator.jpg
Now set the OEM aside and move on over to the PWR. Here, you will note that you now need the 6 new machine screws (not sure what pitch, but 10mm, probably 1.00 pitch). The PWR has metal sleeves for the fans to bolt to, as the OEM had plastic and used self-tapping screws. I had a supply to choose from, so. NOTE: they are the exact same pitch as the screws used for the overflow tank. Be sure that the fans go on in the correct order, as there is a lip on the left hand fan. Mount the fans to the PWR and attach the coolant tank overflow line.
Now we can move on over to the thermostat. I removed the front grill, as this made getting to the thermostat housing easier. Remove the 2 bolts to the housing (where the lower radiator hose attaches) and remove the housing cover. You'll then see the thermostat. You can use the flathead to pop the thermo loose from the block. Note that the jiggle pin is at 12 o'clock. Now you need the sandpaper or the scratch pad to clean off the thermo housing. Once clean, take the Zero/Sports thermo and install it just as the OEM came out. Be sure you do not insert backwards, it will fit wrong!!! Then replace the thermo housing cover and torque it down to 4.7 ft-lb
OK, back to the radiator- replace the lower radiator hose. Now take the PWR and insert it into the car and seat it into the lower support brackets. Reattach the lower radiator hose and the fan electrical connectors. Reinstall the 2 smaller coolant lines (not the upper radiator hose!!). Now that the radiator is in the car, time to fill it. Using the funnel and some plastic tubing, start to fill the radiator with coolant mix (mix it depending on your application/enviornment). The radiator should hold approx. 1 gallon or a lil less. Once the radiator is full, attach the upper radiator hose. Now fill the overflow tank and the remote coolant resovoir with coolant. You should use up almost 1.5 gallons. Start the car with the remote reovoir cap off. The level will go down, so just add a bit until the level steadies (this allows the air in the system, if any, to purge out- I recommend running the car 15-20 minutes). And now, voila- new super cool system. Also, a side note, I added a bottle of WaterWetter to the system during this install- I recommend it also. IF you get a reading that the system is overheating, you still have air in the system- repeat the purge process. Now, go out drive and enjoy!!
http://69.13.78.254/albums/1003/Kopf_Jager/PWR.jpg
PWR radiator
Zero/Sports cool thermo w/ gasket
2 gallons radiator coolant (new radiator takes right at 1.5 gallons of coolant)
6 new hose clamps (good time to change them)
high grit sandpaper (1500+) or scratch pads
torque wrench
12mm (your choice, socket is good)
14mm (same as above, your choice)
flathead screwdriver (for hose clamps and fan plugs)
*6 new machine screws (for mounting fans and overflow tank)
funnel with plastic tubing (for filling the radiator)
Catch pan for coolant
OK, so we're ready? Right! First, ensure car has sat for at least 3 hours- coolant retains heat very well. First, begin with removing the coolant overflow tank. Simple, just 2 screws and a hose. Then remove the air intake duct and radiator supports (12 & 14mm). Remove small coolant hoses on the left of the radiator (coolant will spill now - make sure catch pan is positioned). Remove upper radiator hose. Now you can get to the fan plugs. The plugs are removed by pulling up, not down, on the tabs (use flathead). Once plugs are removed, you can probably get to the lower radiator hose and remove it (may require going underneath the car- I didn't have to). Coolant will now really flow, so repositon pan prior to removal. Detatch the power steering line from the support clip on the radiators right side. Allow system to empty. Now the radiator is ready to remove. Best way is to pull up from the top and to the right.
Here we can see the size difference in the bad boy (PWR) and the OEM:
http://69.13.78.254/albums/1003/Kopf_Jager/PWR-vs-OEM.jpg
Now that the radiator is out, time to remove the fans (use 10mm) and the overflow tank line
http://69.13.78.254/albums/1003/Kopf_Jager/OEM-radiator.jpg
Now set the OEM aside and move on over to the PWR. Here, you will note that you now need the 6 new machine screws (not sure what pitch, but 10mm, probably 1.00 pitch). The PWR has metal sleeves for the fans to bolt to, as the OEM had plastic and used self-tapping screws. I had a supply to choose from, so. NOTE: they are the exact same pitch as the screws used for the overflow tank. Be sure that the fans go on in the correct order, as there is a lip on the left hand fan. Mount the fans to the PWR and attach the coolant tank overflow line.
Now we can move on over to the thermostat. I removed the front grill, as this made getting to the thermostat housing easier. Remove the 2 bolts to the housing (where the lower radiator hose attaches) and remove the housing cover. You'll then see the thermostat. You can use the flathead to pop the thermo loose from the block. Note that the jiggle pin is at 12 o'clock. Now you need the sandpaper or the scratch pad to clean off the thermo housing. Once clean, take the Zero/Sports thermo and install it just as the OEM came out. Be sure you do not insert backwards, it will fit wrong!!! Then replace the thermo housing cover and torque it down to 4.7 ft-lb
OK, back to the radiator- replace the lower radiator hose. Now take the PWR and insert it into the car and seat it into the lower support brackets. Reattach the lower radiator hose and the fan electrical connectors. Reinstall the 2 smaller coolant lines (not the upper radiator hose!!). Now that the radiator is in the car, time to fill it. Using the funnel and some plastic tubing, start to fill the radiator with coolant mix (mix it depending on your application/enviornment). The radiator should hold approx. 1 gallon or a lil less. Once the radiator is full, attach the upper radiator hose. Now fill the overflow tank and the remote coolant resovoir with coolant. You should use up almost 1.5 gallons. Start the car with the remote reovoir cap off. The level will go down, so just add a bit until the level steadies (this allows the air in the system, if any, to purge out- I recommend running the car 15-20 minutes). And now, voila- new super cool system. Also, a side note, I added a bottle of WaterWetter to the system during this install- I recommend it also. IF you get a reading that the system is overheating, you still have air in the system- repeat the purge process. Now, go out drive and enjoy!!