Coolant and Heating System overhaul 1

Replacing metal pipes with plastic

Introduction

Ermie571: (Emma) Problem……leaking radiator, temp repair on metal cooling pipe that needed doing properly

Vehicle = A reg converted panel van. Originally 1.9, now 2.1 Cooling system….mixture of early 1.9 and late 2.1 Mechanical competence = happy to give it a go, but no expert!!! This is a beginners guide, and has tips for those, who like me, don’t know the ins and outs of their bus, but are picking things up along the way.

Tools needed

• Screw driver set – flat and cross heads
• Hammer
• Socket set
• Stanley knife
• Circlip pliers
• Adjustable spanner (needed for removing the thermoswitch from rad – was too deep for the socket set, and didn’t have a ring big enough!)
• Hacksaw for cutting metal pipes to remove if desired, and to use as joining pieces if needed

Parts needed

• Jubilee clips – we put all new on
• Fuel line and clips
• New filler cap metal ring (mine had rusted through – had spare in garage)
• May need to replace other parts of fuel system – neck, breather hoses etc depending on how well they come off
• Plastic pipes
• Rubber hose

The work

Before you start it may be worth carefully noting which pipe joins to where….mark them, or write it down etc….ie where each front to back joins to at the radiator end and at the engine end! Silly, obvious and damn frustrating when you didn’t do it!! Also good to mark the front and back of the replacement pipes – again, obvious, and we did get it right from memory…but we did check the orientation with our other van as we were not 100% sure.

Also, the plastic pipes are slightly bigger than the metal ones. Ours, second hand, came with some hoses. We had to make joins where pipes didn’t fit – used bits of the old metal pipe to provide a solid union on which to clamp the rubber hoses.

What we did. NB – There was little water in the system…and what was in there we drained down the previous day by releasing as many hoses as we could!!

a)drop radiator: followed advice on forum – came out easily, but the following may help those who haven’t done it before! Start by removing the spare tyre – put it to one side; it could be a little while before it goes back! Now you need to remove the metal dish that supports the spare wheel….start by removing the U shaped clips on the metal arms that run underneath the rad to support the dish. Once these were out, we had to hit the metal arms at the hinge with the hammer – they were well rusted in there. Once they were out that end, a quick twist removed them from the front of the van. Arms and dish stacked up with the spare tyre. Remove all the grills. Undo electrics on the radiator. Remove and store the heat sensor screwed in the front of the rad. You will need an assistant for the next bit…..we had 2 of us to hold the rad, while John was underneath undoing the bolts. 4 bolts – 2 on each bracket. Came out easily enough, and the rad lowered straight down. Job done. NOTE – at each corner of the radiator there is a little lug, which has a rubber washer on it. These stop the rad rattling / moving on its mountings. Make sure you keep these in a safe place!

b)Lower the petrol tank – try do this with as little petrol in it as possible!!! We had less than a ¼ tank – still managed to lose some! Again – an assistant is advisable! Need to disconnect the fuel filling system….3 screws at the filler neck – and once mine came to bits it revealed…the rubber filler neck had cracked and split, the metal ring behind it had rusted through, the filler tube itself was fine. Breather hoses and tanks were fine too! The tube just pushes into the tank – turn it, wiggle and pull to remove it. Have a selection of “bungs” handy to shove in fuel lines to stop the loss of petrol – pencils, chopsticks, bolts etc all useful. Gets a bit vague here….as I had to leave to go get replacement fuel line as some of mine was showing wear…. But the lads undid the bolts that hold the straps up, then lowered tank. We did have the trolley jack underneath it to give a little extra support as well. It just hooks on the chassis at the near the front of the van.

c)With the spare out, and the tank dropped, it was time to remove the metal pipes. Pulling, pushing, twisting and shoving all came in useful here. Looking back, it would probably have made the easier if we had cut the pipes…..but had no decent hack saw. They did come out eventually.

d)Stopped for cup of tea and a break.

e)Built up courage to insert first plastic pipe. Had three people doing this….bit of overkill? Pipe doesn’t slide in easily….have to twist it etc to get the kinks through the chassis. This first one went in from the radiator end….not sure if it would have been easier from the other end!

f)There was no way the second pipe was going in from the radiator end!! So, pushed it in from the rear. Got there eventually. Did not have to adjust the hole in the chassis.

g)Replaced the radiator (exact reverse of fitting), connected all the hoses, making joins where necessary. Refit petrol tank, replacing fuel line as necessary. Refit the fuel filler neck in the body, then refit the the filler tube. Needs a bit of wiggling and pushing to get it all lined up.

h)Fill with water and test for leaks

i)Drain, fill with correct water anti-freeze mix, bleed and drive!!