In an earlier project (see appropriate link on this website), I replaced the radiator on my 1978 Jaguar XJ-S. The radiator (designed for a 1990 model) has three rows instead of the original four. Cooling was not a problem, however the new radiator was approx. 1/8 inch narrow than the original. This resulted in a gap (pictured below) between the radiator and the fan shroud.
There are a number of ways to remove the fan shroud. None is easy. Invariably, I recommend removing the top radiator support. This will allow access to the fan screws. I strongly recommend using gloves to remove the fan screws. The radiator fins are unforgiving to skin.
The fan must be removed first, then the fan clutch. Note that I have replaced my fan clutch with an adapter that allows me to use a generic aluminum flex fan.
The fan shroud is removed in two parts. The screws are difficult to get to. Don't forget the screw on the bottom.
Inspecting the fan shroud reveled that the rubber flaps at the base of the electric fan no longer worked properly. Age had made the rubber brittle and hard. These flaps are designed to open at highway speed to allow more air to flow through the radiator. When the electric fan is on the flaps are supposed to close. With a properly functioning cooling system, overheating at speed is not a concern. I removed the rubber strips and riveted aluminum stock over the openings.
I used 4 feet of vinyl baseboard cove molding (available from Home Depot or any similar store) as the donor material for fabricating the seal between the radiator and fan shroud.
Cut the cove molding by measuring 1/8 inch more (or whatever the space is between the fan shroud and radiator) than the rubber strips on the edge of the fan shroud. Make sure you use the curved part of the molding. This will allow the material to compress properly.
Be careful with your measurements, you only have enough material to do this once.
Drill and pop rivet the cut vinyl strip on the side of the fan shroud. Use washers between the rivets and the vinyl.
Rivets completed on the small electric fan side.
Fan shroud modification completed.
The reason the complete fan shroud has to be separated is that it's wider than the space between the upper radiator hoses. I removed the upper radiator hose on the electric fan side, bolted the shroud together and installed the fan shroud as one unit.
Note the new vinyl side molding riveted to the fan shroud.
Side gap between fan shroud and radiator is now sealed properly.
The locating pin on the special fan clutch washer must be used and aligned properly. Pictured below is the hole that the pin goes into.
Align special washer with hole in fan jockey.
I recommend a thread locker (Locktite) on this bolt. Tighten to 25 to 30 ft. lbs.
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