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Installation

  • Introduction

      To assist you in installing your new automotive part correctly our experienced team at Nationwide Auto Parts are pleased to offer you this general guide.

      This is a general guide only and should not be taken over the advice of a qualified automotive technician.

      If you are not confident in repairing your own vehicle DO NOT ATTEMPT TO.

      Nationwide Auto Parts are not liable for any damages caused to your vehicle based on this guide or any repairs you have made to your vehicle.

  • ALTERNATOR

      The following is a general guide to the removal and installation of an alternator. Some alternators are more complex to fit.

      WARNING: YOUR ENGINE MUST BE COOL WITH THE IGNITION OFF BEFORE ATTEMPTING TO INSTALL YOUR ALTERNATOR TO PREVENT BURNING OR INJURY ON HOT PARTS.
      1.
      Disconnect the battery to prevent accidentally touching the positive wire onto an earth.
      2.
      Once the battery is disconnected you can remove either the plug or feed wire on the alternator and the main positive lead (usually located at the rear of the alternator.)
      3.
      Next you will need to remove the belt. Loosen off the pivot bolt at the bottom and undo the locking nut at the top. This will then allow the alternator to pivot and the belt should now be able to be removed. If you are removing the belt completely take note of how it runs over all of the pulleys.
      4.
      Once the belt is off you then can remove the pivot bolt and locking bolts completely. Now you can remove the alternator.
      5.
      Check that the new alternator matches the existing alternator. Swap over any extra brackets or parts from the existing to the new.
      6.
      To install your new alternator, follow the above procedure but in reverse order. Refit the alternator, refit and tension the belt, reconnect the wiring and start your car.
  • CATALYTIC CONVERTER

      The following is a general guide to removal and installation of catalytic converters.

      WARNING: ENSURE YOUR VEHICLE IS ON SOLID, FLAT GROUND BEFORE JACKING YOUR CAR UP AS YOU WILL NEED TO WORK UNDER THE VEHICLE TO COMPLETE THE INSTALLATION.
      YOUR VEHICLE MUST BE SUPPORTED BY JACK STANDS. NEVER WORK UNDER A VEHICLE ONLY SUPPORTED BY THE CAR JACK.
      CATALYTIC CONVERTERS SHOULD ONLY BE INSTALLED BY AN EXPERIENCED PERSON WHO WILL FOLLOW ALL OF THE NECESSARY SAFETY PRECAUTIONS.
      1.
      Jack your car up to a suitable height for you to fit underneath it and stabilise with jack stands.
      2.
      Before loosening the bolts which connect your catalytic converter to the car, spray penetrating oil on them and then proceed to loosen them with a socket wrench.
      3.
      Remove the heat shield if present.
      4.
      You can now remove the old catalytic converter. If required a gentle knock with a hammer should assist you with removal however be cautious not hit other parts of your exhaust system.
      5.
      Ensure your new catalytic converter is the correct size and begin to fit by holding in the correct area and tightening all of the bolts.
      6.
      Reinstall the heat shield.
      7.
      Start your engine and check for any leaks. If leaking, tighten bolts in the area where the leak is and start your car again.
  • COMPRESSOR

      The following is a general guide to the removal and installation of a compressor.

      WARNING: ANY WORK THAT REQUIRES DEGASSING OR REGASSING OF AN AUTO AIR CONDITIONING SYSTEM MUST BE CONDUCTED BY AN AUTHORISED OPERATOR. DO NOT ATTEMPT TO DEGAS OR REGAS A CAR AIR CONDITIONING SYSTEM YOURSELF.

      Do not commence the below process until all gas has been removed from your car's air conditioning system by an authorised operator.
      1.
      Disconnect the high pressure and low pressure hoses at the compressor. Move the hoses out of the way so you can access the compressor bolts.
      2.
      Loosen off the compressor belt tensioner so that the belt can be removed. Take care to note how the belt runs so it can be refitted the same way.
      3.
      Undo the mount bolts that connect the compressor to the engine (or the mount system). Remove the compressor from the engine bay.
      4.
      Place the new and existing compressors side by side and check that you have the correct part. Swap over any brackets or wiring from the existing to the new.
      5.
      THIS STEP IS VERY IMPORTANT. You must know whether the compressor has enough oil. Almost all new compressors come complete with the correct charge of oil but make sure you check the instructions. If you are still not sure tip the compressor on its side and see whether any oil starts to come out. If nothing comes out then you need to add the correct charge of oil.
      6.
      To install your new compressor, follow the instructions above but in reverse order. Fit the compressor, fit and tighten the belt and reconnect the hoses with NEW orings. Once this is done the car is ready to regas.
      7.
      Regassing should only be undertaken by an authorised and licensed operator. They will know the correct procedure and the correct quantity of gas to use.
      8.
      We recommend both the filter dryer be changed and that UV dye is used when regassing. Depending on the reason for the compressor failure you may need to change the TX valve as well. Any licensed air conditioning service center can advise you further.
  • CONDENSER

      The following is a general guide to the removal and installation of a condenser.

      The condenser is the high pressure air conditioning part in front of the radiator.

      WARNING: ANY WORK THAT REQUIRES DEGASSING OR REGASSING OF AN AUTO AIR CONDITIONING SYSTEM MUST BE CONDUCTED BY AN AUTHORISED OPERATOR. DO NOT ATTEMPT TO DEGAS OR REGAS A CAR AIR CONDITIONING SYSTEM YOURSELF.

      Do not commence the below process until all gas has been removed from your car's air conditioning system by an authorised operator.
      1.
      Firstly you will need to assess whether the radiator or the bumper bar needs to be removed. Some cars require the complete radiator to be removed (see radiator installation guide). Others need only the bumper removed or the radiator top mounts removed.
      2.
      Once the bumper or the radiator is removed the inlet hose and outlet pipes can be disconnected.
      3.
      The condenser mount bolts can then be undone and the condenser can be removed.
      4.
      Inspect the condenser and make sure it matches the new condenser you are about to install.
      5.
      To install your new condenser, follow the instructions above but in reverse order. Fit the condenser, reconnect the hoses and pipes with new orings, refit bumper or radiator and then the car is ready for a regas.
      6.
      Regassing should only be undertaken by an authorised and licensed operator. They will know the correct procedure and the correct quantity of gas to use.
  • EVAPORATOR

      The following is a general guide to the removal and installation of an evaporator.

      The Evaporator is the low pressure part of the auto air conditioning system that is usually inside the car behind the dashboard. It integrates with the heater and the fan to give you cooling inside your car.

      WARNING: ANY WORK THAT REQUIRES DEGASSING OR REGASSING OF AN AUTO AIR CONDITIONING SYSTEM MUST BE CONDUCTED BY AN AUTHORISED OPERATOR.
      DO NOT ATTEMPT TO DEGAS OR REGAS A CAR AIR CONDITIONING SYSTEM YOURSELF.

      Do NOT commence the below process until all gas has been removed from your car's air conditioning system by an authorised operator.

      Every car type requires a different process to remove the evaporator. If you are unsure what to do you will need either a comprehensive workshop manual or you will need to visit an experienced mechanic. Some cars can take 1 hour to remove and refit, others can take 8 hours.
      1.
      Before you commence it is good practice to disconnect the battery terminals as the dashboard area has a lot of wiring behind it.
      2.
      Most evaporators are located near or next to the heater therefore the complete heater/evaporator box needs to be removed. If this is the case both the evaporator connections and the heater pipes must be disconnected under the bonnet. Any heater box mount bolts under the bonnet must also be undone.
      3.
      The next step is to follow the process inside the car's workshop manual to remove the evaporator. This section is specific to the actual car you have and varies from model to model.
      4.
      Once the evaporator is out, check that the new one matches the old one and reinstall.
      5.
      Finally, the car must be regassed. Regassing should only be undertaken by an authorised and licensed operator. They will know the correct procedure and the correct quantity of gas to use.
  • FAN CLUTCH

      The following is a general guide to the removal and installation of a fan clutch.

      The fan clutch is located on the fan which is on the water pump.

      You will need to use the appropriate sized socket, ratchet, wrench to complete the removal and installation process. Typically there are two different types of fans used in cars. One with four bolts and one with a single large nut. Depending on which type of fan you have will depend on which tools you will require.

      1.
      Firstly you will need to disconnect your battery at the negative side. Once the battery has been disconnected you will need to remove the fan shroud to access the fan clutch. To do this you will need the appropriate sized socket and ratchet to remove the bolts. You may need to remove the top radiator hose so that the shroud can successfully be removed. Don't forget to drain all coolant from your radiator.
      2.
      To remove the fan clutch you will need to loosen the retaining nut by turning it counter clockwise. Using the appropriately sized wrench, you will need to remove the nut or nuts which hold the fan to the water pump (depending on if it has four bolts or one large nut).
      3.
      Remove the fan blade from the fan clutch and install the fan blade to the new fan clutch. Insert all of the bolts before you start to tighten them.
      4.
      Once the bolts have been installed you can now install the fan clutch to the water pump and spin clockwise to tighten.
      5.
      You can then tighten the fan clutch retaining nuts.
      6.
      You will then need to reinstall your fan shroud and radiator coolant as per the manufacturer's instructions.
      7.
      Make sure you check that the fan blade is clear of any obstructions before starting your vehicle.
      8.
      You will then need to reattach the negative battery cable.
  • HEATER CORE

      The following is a general guide to the removal of the heater core element from a vehicle.
      As they are located inside the vehicle under the dashboard in most cases, you will need either experience or a full workshop manual and patience.

      WARNING: ANY WORK THAT REQUIRES DEGASSING OR REGASSING OF AN AUTO AIR CONDITIONING SYSTEM MUST BE CONDUCTED BY AN AUTHORISED OPERATOR.
      DO NOT ATTEMPT TO DEGAS OR REGAS A CAR AIR CONDITIONING SYSTEM YOURSELF.

      Do NOT commence the below process until all gas has been removed from your car's air conditioning system by an authorised operator.

      1.
      Disconnect the heater hoses near the firewall by undoing the hose clamps.
      2.
      The next step is inside the vehicle and requires the removal of all the dashboard sections as you need to get to the heater core and/or the heater box unit. This is the section where a full workshop manual will take you through the process step by step.
      3.
      Often the heater core is located next to the evaporator. If the evaporator unit needs to be removed as well, the air conditioning system will need to be degassed by a licensed and authorised auto air conditioning specialist.
      4.
      Once the heater has been removed from the vehicle, compare it to the new unit and reverse the process for reinstalling the new heater.
      5.
      Always use new hose clamps when reattaching the hoses. The car can then be regassed. Regassing should only be undertaken by an authorised and licensed operator. They will know the correct procedure and the correct quantity of gas to use.
      6.
      Once the car is all back together, make sure you completely flush the whole cooling system removing all of the old coolant before refilling the car with quality coolant.
      7.
      Run the car with the heater on and the fan going making sure it heats up correctly and that all of the air is removed from the cooling system. Once the car is cold, recheck the water level and top up if necessary.
  • HEATER TAP

      The following is a general guide only as to how to replace a heater tap.
      1.
      Most heater taps are located under the bonnet and require only a screw driver to remove.
      2.
      Once identified and located, remove all of the hose clamps off the old heater tap.
      3.
      Remove the tap and check it against the new replacement heater tap.
      4.
      Reinstall the new heater tap and replace all hose clamps as these often leak if reused.
      5.
      Top up with coolant, run the vehicle, inspect the hose clamps for leaking and check the rest of the cooling system.
  • INTERCOOLER

      The following in a general guide to the removal and installation of an intercooler.
      1.
      Firstly you will need to ensure you have the appropriate tools to remove and install your intercooler. You will need a socket wrench and sockets as well as a flat head screw driver.
      2.
      Remove the bolts which hold the bypass valve on.
      3.
      Use your flat head screw driver to unscrew the two bolts that hold the hose in place. Loosen these as much as possible.
      4.
      Remove all hoses that are connected to the intercooler.
      5.
      Unscrew the bolts which hold the intercooler to the frame.
      6.
      Remove the intercooler being careful not to damage any other parts while you are moving it.
      7.
      To install your new intercooler you can follow the above instructions but in reverse order.
  • MUFFLER

      The following is a general guide to removal and installation of a muffler.

      Your muffler is located at the rear of the car. It is a large, oblong shaped container within the piping system.

      WARNING: ENSURE YOUR VEHICLE IS ON SOLID, FLAT GROUND BEFORE JACKING YOUR CAR UP AS YOU WILL NEED TO WORK UNDER THE VEHICLE TO COMPLETE THE INSTALLATION.
      YOUR VEHICLE MUST BE SUPPORTED BY JACK STANDS. NEVER WORK UNDER A VEHICLE ONLY SUPPORT BY THE CAR JACK.

      MUFFLERS SHOULD ONLY BE INSTALLED BY AN EXPERIENCED PERSON WHO WILL FOLLOW ALL OF THE NECESSARY SAFETY PRECAUTIONS.


      1.
      Jack your car's rear up and stabilise with jack stands or raise with a car lift.
      2.
      Check to see how your muffler is held in place ie: welded intot he exhaust, held with pipe strips or U Bolts.
      3.
      Measure and draw a mark on the exhaust pipe where your new muffler will fit and cut it to the correct length.
      4.
      Carefully and precisely cut the old muffler out of the exhaust system to ensure your new muffler pipe will fit tightly.
      5.
      Remove the remaining tailpipe section of exhaust tubing from the exhaust system hanger.
      6.
      Slide one end of the muffler over the existing exhaust tubing with the muffler straps securely around it and once in place begin to tighten the straps.
      7.
      Ensure you tighten the straps evenly to ensure no future leakage from an uneven torque.
      8.
      Insert the tailpipe end of the exhaust tubing into the other end of the muffler and reinsert the exhaust hanger hook into the exhaust hanger.
      9.
      Tighten the muffler straps securely and evenly.
  • OVERFLOW BOTTLE

      The following is a general guide to replacing an overflow bottle.

      Overflow bottles are located under the bonnet and require small spanners and screwdrivers to replace.

      WARNING: ENSURE YOUR COOLING SYSTEM IS NOT PRESSURIZED OR HOT BEFORE ATTEMPTING TO INSTALL YOUR PART TO PREVENT BURNING OR INJURY ON HOT PARTS.

      1.
      Disconnect the attached hoses from the overflow bottle.
      2.
      Remove the old bottle, check it matches the new overflow bottle and reinstall the new one.
      3.
      Reattach the hoses with new hose clamps. Top up the coolant.
      4.
      Run the car up to operating temperature and check that all the cooling system is functioning correctly.
  • RADIATOR

      The following is a general guide to the removal and installation of a radiator.

      WARNING: YOUR ENGINE MUST BE COOL WITH THE IGNITION OFF AND THE NEGATIVE BATTERY CABLE REMOVED FROM THE BATTERY BEFORE YOU COMMENCE THE INSTALLATION OF YOUR RADIATOR.

      1.
      Inspect the whole cooling system including the hoses, the water pump area and heater tap as well as checking for the existence of stray current. Any current in the cooling system must be repaired or neutralised.
      2.
      Remove the radiator pressure cap and the water hoses.
      3.
      Disconnect the oil lines by hand wrench (if applicable) taking care not to kink the oil lines or strip the fitting threads. Block the ends to ensure no loss of transmission fluid.
      4.
      Disconnect the overflow pipe and heater return lines then remove the upper mounting brackets. Remove the fan shroud or move it to the side to ensure safe removal of your radiator.
      5.
      It may be worth removing the thermostat and inspecting it. Any thermostat that has any score marks on the centre section should be replaced. This indicates that at certain times the thermostat has been sticking. Many radiators have failed due to faulty thermostats.
      6.
      A sticking thermostat will cause your new radiator to fail. Replace the thermostat if you are unsure.
      7.
      Separate the condenser from the radiator and hold the condenser in place.
      8.
      IMPORTANT STEP MUST BE UNDERTAKEN: The whole cooling system (with the heater on) needs to be flushed before the radiator is removed. Drain the cooling system completely and refill with fresh water only. Run the engine with the heater on for 10 minutes and then flush completely again with fresh water. With most cars you will be able to connect a standard garden hose into the heater pipe to aid flushing.
      9.
      Once your vehicle is cool you can remove the radiator.
      10.
      Check that the old radiator and new radiator match. Swap over any clips or nuts from old to new and you can then begin to reinstall your new radiator. Always replace hose clamps as very often they do not hold the correct tension once used.
      11.
      Place the new radiator into position very carefully leaving the mounting bolts loose until all lines and hoses have been connected. Connect oil lines by hand and reconnect the radiator hoses and overflow tube.
      12.
      Tighten the mounting bolts for the radiator and fan shroud and double check everything is connected securely.
      13.
      Fill the radiator with an ethylene glycol based coolant at minimum 50% ratio and top up with water. Run the motor and depending on the vehicle you may need to bleed the system of air through the cooling system bleed screw. Allow the vehicle to warm up until you have confirmed that the thermostat has opened and the thermo fans have cycled on and off.
      14.
      Re-inspect the complete cooling system for leaks around hoses etc.
      15.
      Top up the radiator with extra coolant if required (be very careful if you are taking the cap off a hot cooling system that is under pressure). Inspect the radiator cap for swelling or cracks in the rubber. If faulty then replace.
      16.
      If you are not comfortable completing the above work then please arrange a qualified mechanic to install your radiator.
  • STARTER MOTOR

      The following is a general guide to the removal and installation of a starter motor.

      WARNING: STARTER MOTORS SHOULD ONLY BE INSTALLED BY AN EXPERIENCED PERSON WHO WILL FOLLOW ALL OF THE NECESSARY SAFETY PRECAUTIONS.
      YOU WILL OFTEN BE REQUIRED TO WORK FROM UNDERNEATH THE VEHICLE DURING INSTALLATION.


      1.
      Disconnect the battery to prevent accidently touching a positive lead onto an earth point.
      2.
      Disconnect both the plug or feed wire and the main positive off the starter motor.
      3.
      Undo the mount bolts that connect the starter motor to the engine/gearbox. You can then remove the starter motor.
      4.
      Check that the old starter motor matches the new unit. Swap over any extra wiring or brackets and reinstall the new starter motor.
      5.
      Reconnect the plugs and main power lead. You can then reconnect the battery and test the starter.
  • THERMO FAN

      The following is a general guide to the removal and installation of a thermo fan.

      Thermo fans are mounted to the radiator or the condenser.

      5.
      Run the car up to operating temperature making sure that the fans come on and go off at the normal range on the temperature gauge.
  • THERMO FANS

      1.
      Disconnect the plugs that connect the fan to the wiring loom.
      2.
      Unbolt the fans from the radiator/condenser.
      3.
      Check the fans match in mount points and wiring plugs.
      4.
      Reinstall the new fans.
  • WATER PUMP

      The following is a general guide to removal and installation of water pumps.

      WARNING: YOUR ENGINE MUST BE COOL WITH THE IGNITION OFF AND THE NEGATIVE BATTERY CABLE REMOVED FROM THE BATTERY BEFORE YOU COMMENCE THE REMOVAL OF YOUR WATER PUMP.

      1.
      Drain the coolant from the radiator and flush the system before replacing the pump.
      2.
      You may need to remove your engine's pulley, fan or fan shroud. If so, remove the fan bolts and take off the fan and shroud together. Check the fan for cracks or damage and replace it if necessary. Lay the fan clutch face down after removal to prevent any damage.
      3.
      Move any parts such as the belts, alternator, power steering pump and air conditioning compressor out of the way to ensure you have easy access to the water pumps.
      4.
      Remove all heater and by-pass hoses that are connected to the water pump including any hose fittings that thread into the pump.
      5.
      Remove the bolts from the water pump and then the pump from the engine. Don't try to force the pump off ensure it is gently removed.
      6.
      After you have removed the old pump, very carefully clean the old gasket material from the mounting surface of the engine. You may also need to wire brush the threads of the water pump mounting bolts.
      7.
      Carefully place the new water pump in place and begin tightening the bolts. You may need to consult your car owner's manual to find out the torque specifications for your car.
      8.
      Once in place you can reconnect the hoses and put anything else you removed back into place.
      9.
      Replace coolant and reconnect your battery cable.


Nationwide Autoparts proudly sell all the following parts:

4X4 EMERGENCY KIT - GATES, ABS CONTROL MODULE, ABS PROTECTION, AERIAL - ANTENNA, AIR COMPRESSOR, AIR FILTER - UNI FILTER, AIR FLOW METER ASSEMBLY, AIR FLOW METER UNIT, AIR INTAKE KIT - K&N, AIR TEMPERATURE SENSOR, ALTERNATOR, AUTO TRANS FILTER SERVICE KIT, BONNET STRUT, BOOT STRUT, BRAKE DISC ROTOR - PROTEX, BRAKE DRUM - PROTEX, BRAKE PAD, BRAKE PAD WEAR SENSOR, BUMPER BAR, CAM ANGLE SENSOR, CATALYTIC CONVERTER, COMPRESSOR, CONDENSER, COOLANT TEMPERATURE SENSOR, CORNER LIGHT, CRANK ANGLE SENSOR, DIESEL INJECTOR, DISTRIBUTOR, DOOR HANDLE EXTERIOR, DOOR HANDLE INTERIOR, EGR VALVE, ENGINE CONTROL UNIT, ENGINE MOUNT, EVAPORATOR, EXHAUST CLAMP, EXHAUST GASKET, EXHAUST MOUNT RUBBER, EXHAUST PIPE, EXTRACTOR/HEADER - GENIE, EXTRACTOR/HEADER - REDBACK, FAN BLADE, FAN CLUTCH, FUEL INJECTOR, FUEL PRESSURE REGULATOR, FUEL PUMP, FUEL TEMPERATURE SENSOR, GLOW PLUG - TRIDON, GRILLE, HEAD LIGHT, HEAD LIGHT PERFORMANCE, HEATER CORE, HEATER TAP, HOSE - LOWER RADIATOR, HOSE - UPPER RADIATOR, IDLE SPEED CONTROL VALVE, IGNITION COIL, IGNITION MODULE, INDICATOR LIGHT, INDICATOR SWITCH, INTERCOOLER, KNOCK SENSOR, MAP SENSOR, MIRROR, MUFFLER, OIL PRESSURE SENDER, OIL PRESSURE SWITCH, OVERFLOW BOTTLE, OXYGEN SENSOR, PERFORMANCE ENGINE CHIP, PICKUP HALL SENSOR, RADIATOR, RADIATOR HOSE KIT, RECOVERY KIT, RELAY - A/C, RELAY - BRAKES, RELAY - ENGINE/ECU, RELAY - FAN, RELAY - FUEL, RELAY - HEAD LIGHT, RELAY - HORN, RELAY - IGNITION, RELAY - INDICATOR/HAZARD, RELAY - MISC, RELAY - POWER WINDOW, RELAY - TAIL LIGHT, ROADSAFE BATTERY TRAY , SAFETY FLAG, SHOCK ABSORBER - KYB, SHOCK ABSORBER - RUGGED, SNATCH BLOCK, SNATCH STRAP, SNORKEL - SAFARI, SOFT SHACKLE, SPARK PLUG - IRIDIUM, SPEED SENSOR, STARTER MOTOR, STRAP DRYING BAG, TAIL GATE STRUT, TAIL LIGHT, TAIL LIGHT PERFORMANCE - APG, TARP, THERMO FAN, THERMOSTAT AND HOUSING, THROTTLE BODY, THROTTLE POSITION SWITCH, TIMING BELT - GATES, TIMING BELT KIT, TIMING CHAIN KIT, TOW HOOK, TOW POINT, TRANSMISSION CONTROL UNIT, TREE TRUNK PROTECTOR, TYRE DEFLATOR, TYRE REPAIR KIT, WATER PUMP, WINCH EXTENSION STRAP, WINDOW MOTOR - EL, WINDOW REGULATOR, WINDOW REGULATOR - EL, WINDOW SWITCH - EL

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