How to replace a Shogun radiator

If your Pajero overheats under load (climbing hills etc) or maybe your current one is leaking or broken, you may need to replace your radiator with a new one.

There are a lot of radiator out there, just have a look at eBay and you will find dozens.

But, there are 2 main types:

1. “Regualr” with plastic tanks

2. Heavy duty, all metal, usually, Aluminum.

The guide will be divided t0 2 parts, first, how to replace the radiator with a “bolt on” one. The second would be the adapting work I had to do on my heavy duty one.

Required tools:

10mm, 12mm sockets.

Bucket for the old coolant.

~2 gallons of new high quality coolant

Pliers /screwdriver to release the hoses

Hoses quick disconnect tool – on case you have the Auto trans connected to the radiator (I disconnected mine and added a separated cooler for it)

Time: ~30 minutes to a “Bolt on” radiator.

To the work…

1.  Remove the bolts of the radiator’s mount and the air inlet:

2. Drain the coolant into the bucket through the draining plug or by disconnecting the lower hose (it is easier to disconnect the lower hose from the thermostat side)

Please notice, the coolant is toxic to animals, please drain it to a safe place.

3. Disconnect the upper hose and the Auto transmission hoses (if any), you may need to access the trans’ hoses from the bottom of the car.

4. Pull the radiator out with the shroud and the lower hose.

5. Move the shroud to the new radiator, keep in mind the lower hose angle and move it to the new radiator as well.

(it might be a good idea to replace the hoses with new ones if you haven’t done it for the last few years)

6 web link. Put the radiator back in place, connect the hoses and fill it with the coolant.

7. Start the engine while the radiator cup is off, let the engine get to the working temperature and let all of the air go out of the system, fill the radiator as needed.

8. After ~15-20 minutes, carefully, close the radiator cup in place and turn of the engine. Fill the coolant tank to the max line.

9. During the next few days, check the coolant level every day and add if needed.

That was the first part, the easy one, replacing the Shogun radiator with a bolt on one.

Second part…

I bought a heavy duty, all Aluminium radiator: (I bought it on eBay, that is the one: Heavy Duty  Aluminium Radiator)

It looks good, but it is not “direct fit”…

In order to install it, I had to change the upper mounts, notice the new holes and the 0.5cm which I cut:

I had to cut the radiator shroud mounts:

Installation was much easier if the manufacture would move the mounts a little. if you know the ability to weld Aluminium then you might do those changes yourself.

Bottom line,

It seems that the radiator works as it should.