Main cooling fan was bad - long story short I asked my kid to watch them since I thought the dual fan mod splict had gone bad and he said both were on.... Lesson learned. Again thanks for the many suggestions and hopefully it's completely fixed (havn't tested it in the 100deg temos here yet but boosted heavily and no probs).
Okie (I've searched the forums first of course) my '00 is overheating (most of my **** is in my sig but here goes) and I just want a sanity check here since it is my DD and I don't want to take the truck to work (think 12mpg @ 80 miles/day):
-2860RS (begi S3 kit, turbo and mani c-coated)
-Koyo thin radiator (the one that's 2x thicker than stock)
-stock rad fans
-16 psi rad cap (from napa)
-bell coolant reroute
-bell air scooper
-bell cold air box
-bell bypass (instead of VTA BOV)
-xede tuned (street tuning sessions) by Bell @ 2K' above sea level (I live ~800 above sea level) and was tuned in the summer (hot summer) for 12 A/F ratio (on the conservative side for both fuel and timing)
-no real temp gauge (just the one in the gauge cluster that sucks)
-Bell's largest FMIC
-FMIC-A/C condensor and radiator are extremely close (so close that you can mess up the fins removing the radiator) to keep air flow going
-dual fan mod (both run when one would run or when A/C is on)
-about 30% coolant mixed with distilled water (no water wetter since it made my resivor look like an alge tank - although I do have some onhand if you all think I should go that route)
-just installed a new water pump (from mazda, old one looked ok..
-new generic (carquest) 160 degree thermostat
I was having probs last summer in cruise conditions with the A/C turned on (with it off I was fine). So I added the Koyo and fan mods and all was good in the 100 degree summers here with 70-80% humidity - I could boost all I wanted with A/C on and no probs after the changes.
This summer is a new story, I drove to the gas station and back (think 4 miles) after letting the car warm up and boosted some on the way (but not on the way back of course to let the turbo cool) and my coolant tank is acting like a coffee percolator - air and water coming from the overflow on the radiator like mad until the coolant tank is empty... Fans are running properly.
I did the water pump, thermostat and rad cap and still same prob. Def have more water pressure with the new pump and the thermostat is def open (top radiator tube is hot and pressurized). I also did belts/oil and painted the valve cover :-) while I was at it.
Now I don't have:
-underbody tray (this is a pita with the air scoop installed)
-any additional ducting at the mouth or insulation added around the radiator (it's a tight fit)
-slim mount fans ? Do they offer higher cfm than stock ?
My Friend is suggesting (some for testing purposes)
-run w/no thermostat
-run pure distilled water and water pump lube (no coolant added)
-seafoam/water clean the head (I'm thinking seafoam after seeing the horror stories on too much water going in) since I do run on the rich side and may have built up a deposit thats turning into a hotspot ?
Could I have a hairline fracture in the head gasket (this happened to a friend of mine on a diff car and caused overheating) ?? But my prob is only on the hot days and I see no coolant in the oil and vise versa and no tell tail smoke from the exhaust ?
Car has ~140K on it now (30K of that is boosted at 11-12psi with relatively conservative timing and fuel) and has been well maintained (regular oil changes with either mobile one or Royal Purple 10w-30 and also has had coolant drained every summer -> winter to change the mixture (never see any gunk in the coolant fyi - it comes out clean).
I also have the oil filter relo part of this kit:
This was on the car when I bought it. If I go to an oil cooler I'd prefer to stick with AN fitted hoses that work with the existing kit (I guess I could buy the whole kit and sell off the parts I don't need also - but I'm short on cash after doing the pump etc and I want a kit with a thermostat).
Any suggestions on this (any of this) are welcome.
What would you use to insulate around the radiator ?? Is there some off the shelf stuff I can get at lowes etc to fill gaps ?
Do I need an the oil cooler (don't get me wrong - I want one and have a good mounting location - it's just a matter of budget and whether it will help solve this issue since I need the car up and running for my 80mi / day commute), if so which would you recommend ?
What can be used for undertray material that I could get locally at lowes etc ? The existing tray will no longer fit (I even cut it up and can't get a nice fit, and I'm not afraid of riveting or using metal tapping bolts etc).
I still wanna know why this is a problem now and wasn't last year ... very odd and on cool days car runs fine.
Any help is much appreciated and sorry for the long post (figured I'd fill in as many gaps as possible). TIA