radiator removal S3 turbo 83

[sidders]

Please can anyone help..i have to remove the radiator due to me shearing off the top anti roll bar securing bolt (i know i know)does the front splitter have to come off,also the fibre glass cowling and the fan cowling etc etc do i need to remove/slacken the air con hoses and also i unscrewed the drain plug,loosened the expantion tank cap and all the coolant came out but when i then undid the bottom hose....gallons poured out all over my head !!!!!!! how can this be..??????

[DickLotus]

Sorry to hear about your trouble.
The front splitter/spoiler can stay in place, you need to undo the front undertray fixings with the radiator hoses off, disconnect wiring to fans. Whilst your doing this, support the undertrays on a jack with a good piece of plywood or similar to spread the load and minimise damage to the finish etc. When you have all the under tray fixings out of the way you can part lower the trays and remove the oil cooler and disconnect the A/C heat exchanger from the rest and support out of the way. Remove trays and coolant radiator and get stuck in!
If your radiator is of any age I would suggest you get re-cored by Serck or similar and repair any parking damage to the trays. Last thing order some new stainless fixings and Penny washers.

Richard

[sidders]

Thanks for the reply but the a/c exchange does`nt seem to be in the way plus the tray/cowling that the coolant rad is "sitting" in can only be loosened/removed by removing all the bolts which hold on the splitter..i have removed the 4 bolts(2 each side) that hold the rad secure but the one peice fibre glass "tray" is enveloping the rad so therefore it appears (to me)that it has to be completely removed ??? i shall grit my teeth and have another go 2moro..also i found a bloke who has put pics of his rad removal on the web...can u do me a favour and have a look yourself and tell me what you think..? sorry to be a pain. the site was http://lotusracer.home.mchsi.com/lotustips.htm

[deecee]

The Tray, complete with Radiator, Condenser and Oil Cooler should Drop Down and you should be able to swivel the entire unit out of the way enough to get at the Sheared Bolt.

You should only have to remove the 3 Bolts holding each side of the Tray, after you removed the Grille, the Screws at the Lip and the Upper and Lower Rad Hoses are Disconnected.

In case you haven't already found it...the Rad Drain Plug is located at the Bottom Right Corner of the Rad.

[sidders]

Thanks for the reply...when you say grille,do you mean front splitter..??

[deecee]

Yes...anything that restricts the Tray from being Dropped Down and Rotated, but don't disconnect the A/C or Oil Cooler.

I just did this Last Weekend and what worked great to support the Tray was one of those Adjustable Mechanics Stools.

[sidders]

Many many thanks to you guys for your invaluable help..i am very grateful to you both..regards Sidders

[Pat H]

deecee said:

Don't disconnect the A/C or Oil Cooler

I agree.

When I did this job I unfastened the duct so that it hung down. I left the condensor and the oil cooler in place.

I found it incredibly awkward to get the radiator out, but eventually managed it singlehandedly.

Part of the problem I experienced was inadequate height clearance and obstruction from the axle stands that I was using.

Look Here

Good luck.

Pat

[deecee]

But he shouldn't have to remove the Rad in order to remove the Sheared Bolt?????

[sidders]

the sheered bolt is the upper anti roll bar support,and the only other way i can get the rest of the bolt out is to find a short reach drill,i have tried heat,tapping the bit round with sharp centre punch,swearing at it etc quite frankly i`m amazed that none of the others sheered,i did use heat and overnight lube..!

[deecee]

Hardware Stores have an 90 degree adapter for power drills thats usually priced around $20...