Replacing raadiator on 1.3

Any tips?
What needs to come off 1st; Bumper?
Anything i need to avoid?
Anything else i should replace while i'm in there?

Bumper first, i'd take the grill off for easier access. Then the bumper bar and the radiator brackets. It's a surprisingly easy job once you do it.

I would replace all the hose clips whilst you are there.

All hose clips i could reach from scrabbling around on the ground under the van have been changed. had no choice as with in the 1st week of owning it, 3 original clips broke & 2 more crumbled when i touched them!

Can i "crimp" any hoses to avoid complete coolant drain? i know its better to get fresh in there.

hmmm, not sure. I had mine off as part of a coolant change. I'm guessing you may increase your chances of getting air in the system by doing that but like i say i'm only guessing.

If you're changing the rad, surely it's better to completely drain, flush, and refill the system. No point in sending old muck into a new rad. I'd think about changing the thermostat at the same time too.

Yep totally agree and flush out the block while there is no thermostat fitted and flush the heater matrix too.

Shopping list:
Good 2 nd hand rad as sorry guys I can't afford a new one & repairing this one will take too long as need this done by end if this coming week.
New rad caps
Thermostat I'm kinda reluctant to change as I have a feeling it's a lower temp one as the rad fan kicks in sooner than the last van I had.

The thermostat wouldn't alter the temperature that the fan kicks in, thats controlled by the temperature sensor. All a lower temp thermostat does is let the coolant into the radiator earlier

Can't afford a new one?

EBay item number 321357732102

Thats the secret link I sent her via PM logi

Total bloody bargain or what!

Thats like the cheapest denso radiator I've ever seen.

Shame I can't find them like that for a 993 as the recore I had done a few weeks back came to like 150 quid

Radiator sorted, 2 new rad caps, thermostat will be ordered today from local car shop.

Any tips on removing the front bumper? am i likely to encounter rusted to hell bolts?
Are the radiator caps the same front/under seat?

Radiator is off, we angle grinder the bracket under Rad off instead if removing the bumper bar ! Toooooooo many rusty bolts & most the bolts sheared off getting bumper/rad brackets off!

But new problem!
As I detached one of the rad hoses, the tap joint has cracked as I slipped & hit it with my hand!

How can I permanently repair this?

Better off getting a replacement, unless you're skilled at metalwork?

Or a mate who is good at brazing.

You must have hit that pretty damn hard!!!

Got the pipe off & asking on FB who local can braize it.
Its a pinprick hole that i probably scraped the rust off as i did have a pair of pliers in my hand when i slipped.

What can i replace the bumper bolts with as 3 of the 4 around the skirt/edge sheared off!

check that little rubber pipe it was connected to for blockages while your there :-)
could you use milliput (or similar) and bandage it up?! :-/

If the pipe is rotten like that scrap it.

A clean break is worth brazing.

But a heap of rot is a waste of space.

If it looks like that there I'd expect it to less than ideal elsewhere.

My bumper bolts sheared off in the same place, i'm driving round without them in at the moment but i intend to drill them out then retap the threads.

you got any of those pipes in stock HJ? if so how much inc p+p

The last 4 i've fitted have been supplied by woody.

I sold my own last decent strangled octopus pipe back in about September last year.

Are you sure your radiator really is leaking, and it wasn't just this?

Yup it was, I could see it dribbling out. The pipe only started after my hand hit it.

I have just had some parts off these people, very quick and nice to deal with,, Call Liz 01843 824893

http://www.ebay.co.uk/itm/2009-Piaggio-LGV-flat-bed-tipper-body-may-fit-Suzuki-Rascal-Hijet-2006-2007-2008-/161305880372?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item258e946734

Sorted for Rad now d1noh, Thanks

Starting to wonder if Smurfy hates me! Radiator springs a leak, as i am removing the bumper to get to the rad, all but 1 bumper bolts shear off from being too rusty. no matter can drill them out & use normal bolts/nut/washer.... as i disconnect the rad pipes from rad.. get covered in coolant, working on sandy/grass mixed with coolant = me muddy all over my back/arms & rad pipe bleed valve springs a leak, OK get it braised (Thank You Ian), New 2nd hand Rad arrives today & i need to take the Fan off old un & fit to new one.. all 3 fan bolts shear off from being rusty. no problem, i can use other bolts to replace them (or et some from Woody)... then.. last kick in the balls (if i had any), there is a metal bung/plug that i need to remove from old to fit to new... no way is that gonna come out as half of its rusted OFF!... on the phone to my mate Woddy who i got the Rad from... Another bung/plug in the post 1st thing tomoz for Friday.... I bet ya my last birthday chocolate that when i drill the sheared bumper bolts that samat will bloody go wrong to add to the mess!

Those little 10mm bolts see alot of weather. Pretty much all 10mm bolts on old vehicles are the same.

I use an impact driver like this to remove them everytime.



Putting heavy force on them with a ratchet or spanner sheers them.

But the rattling torque action of the impact driver peels them out without snapping.

Some might say they wouldn't want to spend £100 on a little impact driver.

But by the time you have wasted 10 hours of your life over the course of a year struggling I'd say it's paid for itself. Plus they are the best thing since sliced bread for screws etc.


I hope your replacing all the hose clips for nice new genuine stainless jubilee clips as you go.... otherwise more than likely it will leak in places.

You could get that bung out of the old radiator because you could just melt/cut the plastic away as you don't need to save the radiator.

Hmmmmm one option on the bung, woods sending another one as the old in doesn't even have a hole to screw it back in!
Mate has an impact drive & never thought to use it!

Remember the first week I owned this van I had to replace 3/4th hose clips because they broke/crumbled? Only been a year since & only found 3 hoses that need new clips.