My Reroute drawing
This is kind of a good example:
Spacer on block (is feeding coolant to the heater core, not tapped for temp sensor though):
1.6L Front Thermostat Cover mounted on top of spacer containing thermostat (returning coolant to upper radiator hose on coldside, ignore the temp sender bung, that has to be plugged as there is no room between the cover and firewall to mount the sensor there):
Last edited by RotorNutFD3S; Feb 26, 2009 at 04:54 PM.
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From: Republic of Dallas
there is a transmission under the spacer.
I used a 30mm plug to block the front.
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From: Chicago. (The less-murder part.)
Nope. Overall, it will look roughly like what RotorNutFD3S posted in message #96 or #121. Just a spacer, open on both ends, with a bunch of fittings in the middle.
On the housing. My thinking is that if a person wishes to use a particular hole, they can install the appropriate NPT fitting into it. If they don't wish to use that hole, they can install the plug. Certain of the holes (the one for the heater outlet, and the one for the stock CLT sensor) will almost always be used, thus no plug need be supplied for those positions.
I like it.
Is there room? Been a while since I looked at one with the tranny and everything attached. If so, any of the CLT sensor threads could go there, though the one for the stock CLT sensor would ideally put the sensor in a stock-like location so the factory wiring can reach it.
I believe that's the idea. I don't think there's anything on the NB is isn't on the 1.8 NA, so those two should work as templates.
Really? That's the part that gave me the most grief when I tried to figure it out for myself.
No! The whole idea is that the thermostat will go on the firewall-side of this spacer, not between the spacer and the head. That pipe is the whole problem with the one you have now.
Go out and look at the front thermostat housing on a stock 1.6 engine. Visualize the rounded cover that the upper radiator hose attaches to. That's what we're going to bolt to the back of this whole thing. The thermostat will live between that cover and the firewall side of the spacer, and that outlet will feed the upper radiator pipe.
Just like Braineack and levnubhin have shown in the pictures they posted. (Brainey's is shown feeding out to the exhaust side, but it's reversible.)
In that case, put a hole in it to fit the 1.6 fan thermoswitch, and sell that piece to the 1.6 guys. This eliminates the need for one of the holes on the spacer.
Hmmm. Thick enough for a 1/8" NPT, probably not enough for a 3/8" NPT without some welding... Or some JB-Weld. 
(regarding a plug to fill the hole)
On the spacer housing or on the tubing portion?
On the spacer housing or on the tubing portion?
What about doing a 3/8 NPT and you can use it for EITHER the gm style sensor or use a reducer fitting for the turbo coolant?
(re: sidebars I and II)
If there is space, as an option, it does not seem like a problem. Can some of these ports be on the bottom of the spacer?
If there is space, as an option, it does not seem like a problem. Can some of these ports be on the bottom of the spacer?
We have a 1.6L and 1.8L motor here. I assume we should be able to fit all this stuff around what is on the motor right?
Going to the radiator, around the intake manifold, that is easy.
The groove is no problem. Why eliminate the welded pipe? Don't you need that to go to the upper radiator hose?
Go out and look at the front thermostat housing on a stock 1.6 engine. Visualize the rounded cover that the upper radiator hose attaches to. That's what we're going to bolt to the back of this whole thing. The thermostat will live between that cover and the firewall side of the spacer, and that outlet will feed the upper radiator pipe.
Just like Braineack and levnubhin have shown in the pictures they posted. (Brainey's is shown feeding out to the exhaust side, but it's reversible.)
We do have a front thermostat block off plate.
(on purchasing the naked spacer)
3/8" to 1/2"
3/8" to 1/2"
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From: Chicago. (The less-murder part.)
And being that I sold my lathe when I moved out here, I kinda need it to come pre-lathed. There isn't a single machine shop in all of Charlotte County so far as I can tell. Mr. Pierce died, and he was the only one I knew of.
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Go out and look at the front thermostat housing on a stock 1.6 engine. Visualize the rounded cover that the upper radiator hose attaches to. That's what we're going to bolt to the back of this whole thing. The thermostat will live between that cover and the firewall side of the spacer, and that outlet will feed the upper radiator pipe.
Stephanie
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If the 1.6 fan sensor is on the front of the head...will it ever get hot enough to come on? (210*?)
The 1.6 gauge senders go in different locations on the NA and NB head, but that's it.
The 1.6 gauge senders go in different locations on the NA and NB head, but that's it.
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3/8" thick steel is enough to seal a 1" NPT fitting. 3/8" is plenty for what we're doing. This is relatively low pressure anyways. 3-4 threads is plenty of contact area for a reliable seal. 3/8-18 NPT at 3/8" thickness = 6.75 threads. Plenty. Now whether a spacer welded on is needed for thermostat clearance or flow considerations is another story.
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It will fit. I had one on b4 I swapped it out to a Kia Sephia piece.
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