How to fit a Gen4 Radiator into a Gen3
Posted: Fri Apr 29, 2016 4:35 pmSo what do you do when Junior comes home with an 8 inch split in the top radiator tank of his MY02 Outback and you have a spare radiator and fan package from a Gen 4?
The Gen 4 radiator goes straight in; the two bottom pins are the same dimensions and in the same location. The top and bottom radiator hose connections are essentially the same and the original hoses connect straight up.
First, You need to relocate the electrical connector for the LHS fan. Drill a 1/4" hole in the shroud and reroute the wiring to the same location as was on the Gen 3. Secure with cable ties.
gifs upload
Next, Drill 2 new holes 40mm either side of the two top tank location screws on the radiator support panel. Put two M8 nutserts into the radiator support panel.
image hosting 5mb
Then, Fit the two Top Tank Support Brackets
picture share
Trim the Air Intake Duct to clear the newly relocated Support Bracket.
print screen
Make a nifty bracket that locates in the old Top Tank Support Bracket M8 hole.
screen capture freeware
Fit the modified Air Intake Duct.
screen capture windows
Live with the new securing location for the Bonnet Support Rod.
screen shot on pc
JOB DONE!
Suppose in an Emergency, a Gen 3 radiator could be used on a Gen 4?
The Gen 4 radiator goes straight in; the two bottom pins are the same dimensions and in the same location. The top and bottom radiator hose connections are essentially the same and the original hoses connect straight up.
First, You need to relocate the electrical connector for the LHS fan. Drill a 1/4" hole in the shroud and reroute the wiring to the same location as was on the Gen 3. Secure with cable ties.
gifs upload
Next, Drill 2 new holes 40mm either side of the two top tank location screws on the radiator support panel. Put two M8 nutserts into the radiator support panel.
image hosting 5mb
Then, Fit the two Top Tank Support Brackets
picture share
Trim the Air Intake Duct to clear the newly relocated Support Bracket.
print screen
Make a nifty bracket that locates in the old Top Tank Support Bracket M8 hole.
screen capture freeware
Fit the modified Air Intake Duct.
screen capture windows
Live with the new securing location for the Bonnet Support Rod.
screen shot on pc
JOB DONE!
Suppose in an Emergency, a Gen 3 radiator could be used on a Gen 4?