K-Swap Radiator, Fan and Thermostat Housing Installation (Civic EG/EK, Integra DC2)

Verified guide ✓ 0 views By FitMyBuild You've done this ✓

Time 2-4 hours

Level Moderate

Steps 13

Done by

In progress You stopped at step of 13.

Caution

Never open a hot cooling system; pressurised coolant can scald.
Keep hands and tools away from the electric fan when the engine is warm; it can start without warning.
Coolant is toxic to people and pets; collect and dispose of it properly.
Disconnect the battery before cutting and crimping the fan wiring.
If you raise the car to reach the lower hose or drain, support it on jack stands.

Introduction

A K-series engine's coolant outlets sit in different places from a D or B-series, so a K-swapped EG, EK or DC2 needs a radiator layout and hoses made for the swap. Hybrid Racing's radiator install guide places its swap radiator, with OE rubber grommets, in the factory A/C location; its full-size swap radiators bolt to the factory lower support tabs but leave no room for the A/C condenser. K-Tuned's driver-side hose kit is made for a 1992-2000 half radiator relocated to the driver side and needs a thermostat housing that points down. Hybrid Racing sells hose sets by engine: K20A/A2/A3/Z1, K20Z3 and K24, and a mix of K20 head with K20Z3/K24 thermostat housing. This guide combines the radiator, fan and adjustable thermostat housing steps. Adapted from a community writeup by Hybrid Racing on guides.hybrid-racing.com (https://guides.hybrid-racing.com/Guide/How+to+install+a+K+Swap+Radiator/77).

Procedure

13 steps

Step 1: Plan the layout before buying parts

Decide whether the car keeps A/C. Hybrid Racing says its full-size K-swap radiator is not compatible with its A/C kit, so an A/C car needs its half-size radiator. Then match hoses to your cylinder head and thermostat housing, and check the hose kit's radiator and mount requirements. For example, K-Tuned's RSX-radiator hoses are listed only with Hasport EKK2 mounts, and K-Tuned notes the full-width RSX radiator needs its mounting tabs modified or moved to fit a Civic.
Step 2: Drain and remove the old cooling parts

With the engine cold, drain the coolant. Remove the factory radiator, fan, hoses and the factory A/C components if the A/C is not being retained.
Step 3: Remove the factory thermostat neck

If you are fitting an adjustable housing, remove the plastic thermostat neck's three 10 mm bolts. Drain the coolant first or it will pour out here.
Step 4: Assemble the adjustable housing

On the Hybrid Racing housing, unscrew the pre-installed threaded plug, slide on the mounting bracket aligned with the logo, and thread in and tighten the hose adapter. If you use pliers, wrap the neck in a shop towel so you do not mark it. If you want a Honda fan switch in the housing, fit it now the same way.
Step 5: Fit and clock the housing

Bolt the neck onto the OEM thermostat housing with the supplied hardware, rotate the outlet to suit your hose route (pointing down for most swap hose kits), then tighten the bolts to 7.2 ft-lb as specified by Hybrid Racing.
Step 6: Mount the fan to the radiator

Push the fan's mounting tabs through the radiator fins with the protective pads between fan and core so the fins are not crushed, then clip and slide the retainers until the fan is tight. Make sure the fan faces the right way for pull or push.
Step 7: Set the radiator in place

Place the radiator, with the fan already fitted, onto the OE rubber grommets in its mounting location. If you need lower brackets, K-Tuned's bolt-on bracket kits use well nuts in two 1/2 in holes; mock everything up first so the brackets suit the hose positions.
Step 8: Fit the drain bolt

Install the radiator drain bolt, with thread sealer if you like.
Step 9: Fit the fan switch and gauge sender

Screw the fan switch into the lower bung and the coolant temperature gauge sender into the upper bung, then connect both to the corresponding wires of your conversion harness. If a K-Pro will control the fan, the fan switch is optional.
Step 10: Fit the hoses

Install the upper and lower hoses with good clamps (T-bolt clamps are common on silicone). Check they clear the transmission counterweights, intake and belt.
Step 11: Wire the fan

Find the factory fan connector near where the original fan sat. Cut off the old plug and crimp on connectors that match the new slim fan, then connect it.
Step 12: Fill and leak-check

Fill the system with coolant, bleed out air, and check every joint for leaks.
Step 13: Confirm fan operation and direction

Let the engine warm up while watching the temperature gauge. When the fan switches on (from the fan switch or the K-Pro setting), check it moves air in the right direction. If it runs backwards, swap the two wires at its connector.

Tips

Hybrid Racing recommends two 10 in high-speed fans with its full-size 1996-2000 Civic radiator.
K-Tuned recommends putting the single-wire gauge sender in the upper hose position on its driver-side kit and offers a fan-switch port in the lower hose.

All guides →

FIG. 2.1

Engine

Honda Civic (EG) Fuel Pump Replacement