This radiator came from an EK. Its been definitely neglected and it was disposed because its clogged and causing the engine to overheat. Easy solution to a clogged radiator is to replace with a new one. It just so happened that I have a lot of free time and decided to rip this radiator apart.


Top cover secured firmly by small clamps





Pry those clamps loose using a flat-head screw driver or anything flat.




After opening it looks like this. Holes clogged




Top part, right. Most of the holes are blocked by rust, salt crystals, sealant etc.



Left part is worse.



Wash it down and flush from the bottom radiator opening




I used an old dipstick to clean deep into the holes.




Bottom part is even worse. Take note of the black lines around the radiator, its the gasket.




After a little cleaning, it improved a lot better.




Crimp back those clamps slowly but snugly. I used a vise-grip to crimp back the clamps.
Remember to clean and check the rubber gaskets between the radiator and cover. Replace if its bad. Now do a pressure test to see if all is well. You might need to do a little more crimping if there is a leak.

 

Ive never seen this done before. Good job, nice write up. what is the advantage of doing this vs replacing the radiator? I bought one with the same plastic end caps for $50.

 

Advantage is you save 50$. You save more if you compare to oem.I bet this repaired oem radiator will provide longer service than most cheap replacement parts.

 

Usually the external fins are pretty shot by the time I replace a radiator. I do a lot of high speed highway driving though.

 

You could provide a medium sized wire mesh in front of the radiator to give it some protection to small road debris.

 

Actually I'm going to hazard a guess that it wont. All you're doing is patching up an up to 20 year old beat up component and hoping for the best. Good to do if you're hard up for cash. Not so good if all you're trying to do is save a little pocket change.

 

The radiator I repaired doesn't seem to be very old. Fins are good, plastic parts are not faded. It was just neglected by the owner. It's not mine. Actually I installed a new two-row radiator on mine. I just see it to be a waste just to throw it away when there's more people having worse radiators than these. I'll probably give it to a neighbor. Even if it dont last, its free. He wont complain.

 

It's going to leak around the tank, just take my word for it. It's hard enough to get them sealed right when they're new. I'm as cheap, actually probably significantly cheaper than the next guy, but come on, a brand new rad for these things is dirt cheap by anyone's standards.

 

not only cheap, but most from auto parts stores have a lifetime warranty.

 

This. Exactly.

 

Lifetime warranty on a new one alone is worth the cost of buying a replacement.

This is a nifty DIY, but in the end I think it's just going to cause more problem when it leaks or causes overheating.