The procedure is as follows: (I did not need chassis stands as my bakkie is high enough to work under)
Tools needed:
- Size 10,12 and 14 socket and or flat spanners
big Phillips screwdriver
flat screw driver
long nose pliers
Use the pliers and remove the spring clips retaining the lower shroud and remove the shroud from the vehicle.
(Pic of shroud with the lower shroud connected and without it connected -already removed from the vehicle) Remove the four (4) bolts retaining the upper shroud and remove from vehicle. (size 12 spanner / socket) In order to remove, you might need to disconnect the inlet hose on the radiator (I had to).
Remove the nuts retaining the the viscous coupling to the water pump pulley. (size 10 flat spanner). If the pulley slips on the belt when you try to loosen it, you could do the following:
Use two flat spanners and loosen the bolt on the underside of the alternator (Size 14 spanner). Loosen the lock nut on the adjusting bar of the alternator (size 12 spanner / socket). Use a lever of some sort to increase the tension on the alternator drive belt and lock the alternator in place again Remove the viscous coupling / fan assembly from the pulley. Please note that there is no need to remove the drive belt or pulley. Remove the four (4) nuts joining the viscous coupling and fan together (size 10 spanner / socket) At this stage go to a clean work area. Use a descent size Phillips screw driver to loosen the four (4) screws joining the two halves of the coupling together. These screws are really tight so make sure you use a screw driver that fits perfectly otherwise you will strip the heads. Use a thin flat screw driver or Carpet knife blade to separate the halves. Take care not to damage the seal. The oil has a very high viscosity so don't worry to much about oil spilling while opening it up. Cut the tip of the oil tube and squirt the oil into the cup-shaped halve of the coupling. Carefully join the two halves again making sure that the seal surface is clean an makes an air tight seal.
The fitment is the reversal of the above procedure. Take note to tighten the bolts on the fan assembly and water pump pulley progressively until all tightened. If you have difficulty tightening the nuts on the pulley, give the alternator drive belt some slack. Make sure to adjust the tension on the alternator drive belt if you loosened any of its locking nuts and make sure all nuts us tightened again. When the shroud is installed, make sure of the clearance between the shroud and the fan blades. Also remember to top up the coolant level if you disconnected the inlet pipe on the radiator.