Note: Refer to the warnings given in Section 1 of this Chapter before proceeding. Hoses should only be disconnected once the engine has cooled sufficiently to avoid scalding.

1 If the checks described in Chapter 1 reveal a faulty hose, it must be renewed as follows.

2 First drain the cooling system (Chapter 1); if the antifreeze is not due for renewal, the drained coolant may be re-used, if it is collected in a clean container.

Models with conventional hose connections
3 To disconnect any hose, use a pair of pliers to release the spring clamps (or a screwdriver to slacken screw-type clamps), then move them along the hose clear of the union.

Carefully work the hose off its stubs. The hoses can be removed with relative ease when new - on an older vehicle, they may have stuck.

4 If a hose proves to be difficult to remove, try to release it by rotating it on its unions before attempting to work it off. Gently prise the end of the hose with a blunt instrument (such as a flat-bladed screwdriver), but do not apply too much force, and take care not to damage the pipe stubs or hoses. Note in particular that the radiator hose unions are fragile; do not use excessive force when attempting to remove the hoses.

5 When refitting a hose, first slide the clamps onto the hose, then engage the hose with its unions. Work the hose into position, then check that the hose is settled correctly and is properly routed. Slide each clip along the hose until it is behind the union flared end, before tightening it securely.

Models with CONRAD “click-on” radiator hose connections 6 Some TU3FM engine models may be fitted with pre-production “click-on” radiator hose connections. These fittings were only fitted to a limited number of vehicles, and have now been discontinued in favour of conventional hose clips.

7 The hose end fitting is retained by a large circlip, which must be extracted before pulling the hose out (see illustration).

2.7 CONRAD “click-on” type radiator hose connection

1 Radiator fitting
2 Retaining clip
3 O-ring
4 Hose end fitting

8 When refitting, first fit the circlip into the radiator fitting, placing the flat part in position first, and bringing the ends into position one at a time.

9 Ensure that the O-ring is in good condition, and securely located in the hose end fitting. It should not be necessary to lubricate the O-ring to fit it, but if any form of lubrication is used, the radiator must be refilled with fresh coolant, to avoid contamination.

10 Align the hose end fitting with the three lugs in the radiator connection, push firmly into place, and check that the hose is secure by pulling back on it.

All models
11 Refill the system with coolant (see Chapter 1).

12 Check carefully for leaks as soon as possible after disturbing any part of the cooling system.