This is probably the first of a number of questions.

While the S4 is off the road, I thought I'd do some work to it. I was surprised when I drained the cooling system at how small the capacity seems to be. I'd like to try to improve it and wanted any thoughts anyone might have.

I know that Andrew has talked in the past of the coolman from GBS, so that's a possibility, also will probably change the fan. Anyone any thoughts on the benefits of push or pull?

John

Was the car over-heating before it came off the road?

Mick.

you dont need to fix what isn't broke. if your car doesn't overheat it's probably ok. Even if it does overheat, are you sure the radiator is the fault? it more usual for kit cars to have badly fitted/sited radiators that need either moving forward or "ducting " to force the air through the radiator, not letting the air to go round.

In the hot weather here it would bimble along at about 90 degrees. when pushed the temp would climb. Air temp here in the summer can be 35 - 40 degrees. It never actually boiled but it did get hot and occasionally I would pull in to let it cool down. I had a bandage from the manifold to the side exit and water wetter in the system.

John

Jaybe,

If over heating was a problem spend money on it, if it wasn't spend your cash elsewhere.

Mick.

The cooling was OK with the 1.8 but became marginal with the 2.0L at average temperatures, with higher ambients and more power the rad needs an upgrade without a doubt and a cooler stat would also not go amiss. - I left the heater in the car to give some additional capacity.

I would fit a Polo rad and a Volvo 740 header tank - the Polo rad had no problem at all with my Westy - they are £45 delivered in the UK and the tanks £5 at the breakers.

That would be a good start.

Andrew

Hi,

Anyone know where I can get a diagram of a cooling system including a header tank?

John

take a look at the gallery section on this web site my old malaga b+ (the first pictures) show a fair amount of what you need. Basically the header tank needs to be the high point in the system, the bottom of the tank should connect to the bottom hose some how, and the top thin overflow pipe should connect possibly to the radiator top, OR the thermostat housing, or some where high up on the cooling system.

Thanks Snowy,

It's pretty much as I thought. I've got a VW rad, a header tank and a pacet heavy duty fan on their way to me now. In the meantime, I'm installing the megajolt and prettying her up a little with silicon hoses and stuff. Having a bit of trouble getting the bonnet over here. I've got a mate who usually drives back and forward with an empty van regularly but I haven't seen him all summer. Hope I can get it here soon, can't wait to get back on the road.

Thanks again
John

Its good if you can get the bleed to the header tank from the pump side of the T-stat this way its at max pressure and will take any air back to the headertank and alway circulate water through it - As snowy says feed from the header to the suction side of the pump.

If you tee the bleed off the rad to the header as well - then you tend to push air back into the rad rather than bleed it out so blank it off or fit a non return valve in its line.

Polo rad also usually mounts on rubber bobbins and will need a 22mm stat to screw in it so dont forget those - the rad mounted in the stat will mean you can swap to a standard Sierra t-stat outlet which has a bleed on it for connection to the header - not sure the Transit one I had fitted does.

Cheers

Andrew

Thanks Andrew,

I think I know what I'm doing now. I'll get onto sourcing the bits. Although it's a bummer not having the S4 on the road, I'm enjoying the work that I'm doing and getting to know the car better.

I'm going on holiday tomorrow for 10 days. Back on the 15th so please don't send the wishbones to arrive before then.

Thanks
John

Ok John - will note that

They are currently kits of parts waiting for me to put a jig together to tack it all up but even in bits they look a lot better than they did - all the parts are straight ;)

Andrew

I'll bet they do!

I discovered the lower front bracket had broken at the weld to the chassis so have re-welded it. My first real job with the welder! I've also now welded the megajolt trigger wheel to the pulley. Don't know if you marked up the crank pulley but, while I had the head off, I put a guage on to find true TDC and the marking is absolutely spot on.

Cheers
John

The kits are now wishbones - took a bit longer than expected but with such nice weather it was just nice to have the opportunity to work outside for a change:D





Just needs John to do the final finishing off knocking off the bits a spatter and giving them a good coat of paint.

John I also have a new rose joint - better replace it just in case.

Will drop you a PM

Andrew

Thanks Andrew, looks good.

I just got around to spending time on the forum and found you post and pictures.

I am fitting the new cooling system now and have decided, while I'm waiting for the bonnet and stuff to go ahead and install the megajolt. Seemed rather silly to go through the hassle of timing the electronic ignition just to take it out again and go through the same procedure with the megajolt.

John

Re Polo radiator and Tstat housing

Just wanted to check with you before I bought it, is it Burton stat housing no FT1074 and the blanking plate that I need?

Also like to check that I've got the plumbing right in my head.

I'm going to try dispensing with the heater, so I think it is as follows:


Top Rad inlet - thermostat housing

Bottom rad outlet - pump

16mm pump outlet to manifold with T to header

T stat bleed outlet to header

Blank off rad bleed

Can anyone confirm this?

John