So I look at the manual section on radiator removal for an '04 XK8 and it says to evacuate the air conditioning system. Seriously?! It looks like the AC condenser is bolted to the front of the cooling system radiator. And it looks to me like the bolts can't be removed with everything in place. Which certainly implies that, yes, the AC system has to be evacuated so the both radiator and condenser can be removed as a unit. Is there any way around it such that the AC can stay undisturbed while the radiator is swapped out?

 

The A/C system does not have to be messed with. Start by removing the fan shroud to make some space. Painful part is a bolt for the sealing bracket by the air box (hard to reach). Expect a no-fun-zone on this job. Then again, when spilling coolant is involved. there is typically no fun involved (Maybe it is just me). What radiator did you get? Make sure the transmission cooler fittings are correct before getting too deep into the job. These changed between the older 5sp and the 6sp. Also, the NISSEN radiator I got had an open nipple on the top driver side that is only supposed to be active on the earliest cars, so be prepared to plug that up somehow.

 

Much appreciated. I haven't bought a replacement yet. Still mulling whether to try it myself or take it to a shop - I've been around several blocks, which means rad replacement should be no big deal, but I'm very close to too old to (want to) mess with it anymore. So once the fan shroud is removed you can get to the bolts to free the condenser from the radiator?

 

I don't remember the exact specifics, but I believe these has to be reached from the front or the bottom. From memory, the driver side bolt is OK, but the passenger side is more of a challenge because there is a foam air dam that blocks the flow of warm radiator air to the air box. The bolt holding the condenser also holds an awkward steel bracket for this foam seal. The job is the usual (long-ish) series of steps, none too difficult, but with occasional challenges especially for someone that has never done it (which I was at the time). This is a job you have to power through, I guess, not much satisfaction in it.

 

Remove the hood first, you'll need a extra pair of hands, a 5 minute job. Accessing/working from the front makes things "easier".

 

That's kind of the direction I was leaning when I scoped it out - get the hood out of the way first. Sounds to me more like 3 pairs of hands - one on each side and a third to release the last couple of bolts. That dang thing sounds awfully heavy when it closes. I suspect that suspending it from above might turn it back into a one person job. At this point I'm just glad the AC system can be left alone.

 

I have had the hood off and back on several times working alone. Use wood props to hold it open far enough to allow removal of four fasteners and leave the last two loose. Then spread a heavy blanket or comforter across the opening and support the hood on a couple of pillows while you remove the last two screws. Add another blanket under the front on the bumper, then slide the hood forward onto another pillow on the floor. You should be able to lift the hood and move it, but another pair of hands would be good if you're not confident.

 

I used the "service Position" instead. It leaves more room than one would think at first.

 

Nice to see people using their heads, RJ237; very creative. I still like the idea of suspending it though.

 

I just replaced my radiator in my 2000 XK8 with a Nissens. I took the radiator out without opening the AC system as others have done. If I were to do it again I would investigate having a mobile AC man come by and evacuating and sealing the system.I would be so much easier to remove the radiator , fans and condenser as a unit as the shop manual shows. It would take 2 people to remove and install the entire unit plus the cost of a recharge and drier. But it would sure save you a lot of time and aggravation.

 

I appreciate the input. Just fooling with the AC system is a lot of time and expense and bother to me. I may feel different afterward, but I like the idea of removing the hood and leaving the AC intact. Will let y'all know how it goes. Will be a couple of weeks before I can get to it.