5.2 - MKIX Lower Radiator Hose Replacement ( RichardL,  January 13, 2003 )

This is the sequence I found that worked for me...

I first removed the Grille assembly. (Two bolts from under the
car, two that go in to the Tie Panel (559). Next I removed the tie
panel, supporting front wing valences and radiator at top (559).
Next I removed the Channel, supporting tie panel (939). Next I
installed the lower radiator hose upper hose clamp (I used a modern
clamp that takes a 5/16'' socket shhhh!) And faced it so I could
get a 1/4'' socket wrench between it and the fan blades. Tightened
it up good (previously had cleaned the fitting throughly). Next I
installed the radiator with the petcock assembly (Darin tap
assembly for radiator block - C5755). I tilted the radiator back
so that the top of the radiator was leaning towards the windscreen
and the bottom could slide in between the fans blades and
the 'Front End Diaphragm Assembly For Radiator (7078). I carefully
lowered the radiator down until it the fitting for the petcock
assembly was just below the fan blades, but above the frame (about
3'' higher than it would normally sit). I used a piece of spare 2x4
to hold it in this position. I slid under the car and installed
the petcock valve, don't forget to include the fibre washer! Next
I got out from under the car, lifted the radiator slightly and
removed the 2x4 piece. I then lowered the radiator in to place and
installed the 4 screws through the 'diaphragm' which hold the
radiator in place. Next I climbed back up under the car and
connected the lower radiator hose to the radiator and tightened
down the clamp. I then extracted myself from under the car and
installed the upper radiator hose. Then I reinstalled the
supporting channel then the tie panel and finally the grille
assembly. Voila, a perfect installation. If only I hadn't had to
take the radiator out and put it back in to get there. Ah well,
the job is done!

As always your mileage may vary, all I know is this worked for
me... though it was likely the hard way at least I didn't have to
take the fan or the diphragm off. I suppose I may have taken some
unecessary risks by not doing so, but by being careful I really had
no issues. It was a darn tight fit and having a second set of
hands would have helped tremendously.