Greetings All,

Any thoughts on new foam seals around the radiator? I'm in the middle of replacing the radiator* on my '02 V6. The foam seals are shot and falling apart. You can see the three pieces in this diagram, items 3, 4, and 8:

https://parts.jaguarlandroverclassic.../brand/jaguar/



Not sure I want to pay OEM prices, but all three pieces are discontinued. I couldn't find any old stock from any third party sources, either.

As far as fabricating something, the pieces are kinda thick, maybe 1.5". I don't think I can find any foam weatherstripping that thick. My only thought is to get some pipe insulation, the kind you wrap around hot water pipes. Or possibly some pool noodles, for playing in the water. Those are the only foam pieces thick enough that come to mind.

Any ideas?

*If replacing the radiator, definitely disconnect the AC refrigerant lines and do a full service afterwards. I read some comments it's possible to remove the radiator with the lines intact, but it was very hokey with tight quarters and lots of swearing. I did manage to remove the radiator, but it looked nearly impossible to get the new one installed without causing damage. I tried removing the AC pressure sensor for extra clearance and the valve stuck open, discharging the system anyway. With the decision already made for me, I disconnected the lines from the condenser and installation was now fairly easy.

Same thing for the plastic panel under the radiator. Some of the screw heads had been ground down from curb contact, so I couldn't grab them with a screw gun. After some frustrating hours working around this panel, I drilled out the screw heads and removed the panel. Big difference, wish I hadn't hesitated to remove the panel.

 

Use foam inserts from the big box stores. Insert after the new radiator is in place.

 

I've found replacing the radiator on an X200/202 to be much less frustrating by discharging the air conditioning system refrigerant first. The cooling lines for the power steering are also a challenge to work around without causing them to break or leak.

It's also a good time to replace the DCCV with the radiator out of the way.

 

Same with the X350 series. Not much room to do anything. I managed to get mine replaced on my 04 XJR w/o discharging AC lines - never again. Literally had to take the entire front end of the car off.

And I thought changing the radiator on my 00 Jaguar 4.0 was a challenge ??♂

 

Don't forget to change the water pump when everything is wide open.