Latest leak....Oil Cooler

[AVI_8]

I noticed drips of oil at the front right side of the car, so took off the plastic wheel lining cover suspecting the oil cooler hoses, here's the result

The top rear end of the oil cooler is leaking and will need to be replaced.

Here's a pic from the other side, the hoses are dry, the connections are a bit rusty so I've soaked them in penatrating oil, hopefully they'll come off without damage, I'll need a large spanner, think it's 30mm, Pelican parts seemingly sell the oil pipe spanner kit but I don't have time to wait for them to come from the US.

Normally I'd replace the likes of hoses when I'm in there anyway, especially as I've stripped off the front end of the car (bumper) but they're maga expensive, so I'll leave them for now. I have a friend who used to work for a company called Pirtek, they make hoses for JCB's and the likes, he said that they would be able to make me new hoses, able to withstand 3000psi, which is overkill but but it's an option if ever they need replaced.

Will post pictures and how to replace the cooler once it's done

 

[C2dweller]

I had the opposite ... suspected the cooler after seeing the drips but felt it was probably the hoses on closer inspection - it seemed to be coming from the radiator joint at the top (there are aluminium washers which could have been replaced...)

I already had the bumper off after having some bodywork done, so decided to fit the new cooler anyway. Without doing a pressure test on the cooler I'll never know. Hardest part was getting hold of 32/36mm spanners. Luckily someone helpled who had more tools than me []

 

[Steve Brookes]

While you're at it guys....post some pics and instructions about removing the front bumper []

 

[AVI_8]

C2 Dweller, is it definatelly 32/36 spanners, I'll need to buy some and don't want to get the wrong sizes,

Steve, I already have my bumper off, have taken some pics and will explain how to do so when I get a chance

 

[Steve Brookes]

Those sizes of spanners don't seem to be available in normal hardware stores. I ended up buying mine (32 and 36) from here:

http://www.alltoolsdirect.co.uk/metric-634-c.asp

 

[AVI_8]

Thanks Steve, they seem quite reasonably priced as well.

 

[C2dweller]

My long term helper was ... my Dad. Stetson (? spelling) and a 32mm is what he had []

Halfrauds have a 32/36 mm combo spanner which is the same as the britool advertised on ebay. Not as cheap as Steve's link though, but good in case of emergency.

 

[AVI_8]

Hi, thanks, I noticed that tool, think it's for a water pump, ordered some spanners from the website steve recommended, while I'm waiting for them, did the CV boots today.............or tried to, will start a thread on that!!

 

[AVI_8]

Finally got some days off to get the new cooler fitted, Steve will also show how to refit the bumper, you asked about this.

Old Vs new cooler

My new cooler came with new Unions fitted (the bit that the hose's screw into so I didn't need the new washers I'd bought)

I fitted a new rubber top mounting as the old one sheared off when I tried to remove it, remove the temereature sender from old and fit with new washer to new cooler.

Remove the four clips from the old cooler, the ones that the fan shroud screws, screw into and fit to new cooler.

Remove the 3 clips from the side, the ones that hold the side plate, and fit to new cooler, The small bolts holding the side plate, Think they're 5.5mm as a 6 was too big and a 5 too small, I removed with a pair of vice grips as I didn't have a 5.5mm socket, they weren't too tight.

Transfer lower rubber mounting thingies from old to new cooler and you'ready to refit, can't remember if I mentioned earlier but the top mounting screws into lower part of headlight surround, held on by an L bracket.

New cooler fitted

Be extremely careful that you don't cross thread the hoses when you're screwing them onto the cooler, there's not a lot of movement of the hoses, use lots of WD40 on the hose nuts and make sure that they spin freely before screwing them onto the cooler.

 

[AVI_8]

Before I could start the engine to check for leaks I had to replace the 2 horizontal hoses from the oil tank I'd removed earlier.

Pic of them fitted

I thought that this was going to be a complete bitch of a job but in fact it was extremely easy using the following method (the hoses are short and there's not a lot of room to flex them into place)

Remove the lower hose at the opposite end, remove the 10mm bolt holding the pipe that goes to the lower hose.

Get a bowl of boiling water and put both hoses in there for 5 mins, this softens them and makes the world of difference when it comes to fitting them.

Smear the pipes with grease so that the new hoses slide on more easily, fit the top one first, fit lower pipe at cooler end first then other end, easy as!!

 

[AVI_8]

Now to refit the bumper, Firstly refit the 2 hoses going to the headlamp cleaning jets, it helps to have someone else to told the bumper loosly in place while you're doing this, my 9 year old son was a good candidate for this!

Locate the bumper correctly, make sure that you take note of exactly how it came off during removal, there's 2 clips which sucurely hold the bumper rubber in place each side. Pic of one here, shown at top right of picture

Refit the top metal reinforcement strip , it's held in place by 4 screws which is located under the seal located under the front leading edge of the bonnet, screw these in loosely for the time being.

There's 3 other metal brackets on the bumper, one located at each side holding the bumper to the wing, and one under the front of the bumper holding the lower side panels to the bumper underneath

, have a look it'll be obvious what I mean. Pic of them here, I've scraped the rust off with my angle grinder, sprayed them with etch primer and then black paint.

 

[AVI_8]

Here's a pic of the side bumper mounting bracket in place, holding the bumper to the wing, the reason I mentioned to loosely fit the 4 screws holding the bracket at the front earlier is because you may need to to move the bumper a few mm left or right in order to get it to fit securely, even a couple of milimetres out will mean that the rubber seal will not seat properly on refitting, it took 30 mins of head scratching to realise this was why mine wasn't initially.

Forgot to mention that you should plug in the fog lights before refitting the bumper, either that or spend half an hour swearing like I did trying to fit them unable to see what you're doing!!
Now you've got the bumper securely in place you need to replace the 2 lower panels which hold the bumper to the car at the lower side. If like me you find that a lot of the screws and clips are slightly the worse for wear, I bought this set from halfords for £8

Just a case of refitting the inner wheel lining now, again you'll probably find that a lot of the clips screws are knackered so I replaced them with new ones.

I'm nearly ready to get my car back on the road now, after the engine service, hoses/oil cooler replacement, Just waiting on a new cover going from the CV joint to the gator, was supplied the wrong one (C4) it's slightly smaller diameter, hopefully get the correct one tomorrow, in the mean time, I cleaned the wheels using a rag with lots of petrol which is the best solvent you'll get. Due to the oil leaks they were covered in oil oil.

Some before and after pics

 

[Steve Brookes]

A bit of an off topic question but....do you know what the bolts inside the boot on the front tub wall are for? A few centimetres below the line of the latch, etc. There's about four of them and I've notice that one of mine is loose and won't tighten.

 

[AVI_8]

Steve

I've had a look, and see the bolts you're talking about, my bumper is back on now so I'm not sure what they're for, it's not for holding the bumper moulding on I can tell you that.