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Old 06-04-2008, 02:31 AM   #1
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Thumbs up My Coolant Re-route

Ok, Sorry this took so long to get pictures up and Im also sorry that the last couple are from my cell phone. First, Here is my design.
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Next I made a plate with an o-ring to make sure it sealed properly.
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Then Buy a 1.8L T-stat housing
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I made this spacer feel free to use my drawing to make your own. I MIGHT be able to make one if someone else if my father allows me to use some more aluminum.
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Another veiw, this one with the 1.6L tstat housing on it. What this doesnt show and I dont have a picture of, is that housing is pluged with a bolt and drilled on the flat surface to allow for the green sensor to go in.
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I also dropped the power steering pump at the same time.. Look at how much more space there is!!
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Just an engine shot
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Uploading the other images as we speak... not going very well
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Old 06-04-2008, 02:41 AM   #2
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From the diagram it appears that the heater core return goes to the stock mixing manifold location, yet the picture of the block with the thermostat neck in that spot reveals no obvious provision for same. >?
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Old 06-04-2008, 02:46 AM   #3
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Alright, I will take more in depth shots next time I work on it...
Veiw from the back (sorry its not clear, its just the spacer, temp sensors, 1.6L tstat housing and a rad line)
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Next it meets up with a Turbo Tim housing and I drilled a hole in it to allow for the throttle body return line.
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Re-used the hoses from the bottom of the Rad at the top.. Worked great!
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And lastly, the Turbo return line goes through the heater core (not in this picture because I broke the weld on the inlet hahaha so this is just temporary.
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Hope you all like it! Comments welcome!!
PS 180* tstat with 2 holes drilled
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Old 06-04-2008, 02:48 AM   #4
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Quote:
Originally Posted by Joe Perez View Post
From the diagram it appears that the heater core return goes to the stock mixing manifold location, yet the picture of the block with the thermostat neck in that spot reveals no obvious provision for same. >?
That hose from the bottom of the turbo is actually an oil return line. I was just having fun in paint one day drawing my setup, so I used that drawing. Heater return goes straigh into my spacer to meet back up with the coolant at the back of the motor.
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Old 06-04-2008, 02:55 AM   #5
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Almost forgot to include my parts list...

parts list:
1.8L thermostat housing
Turbo Tim inline thermostat housing (needs to be drilled to accept a fitting.
(2) 1/8" NPT to 1/4 barb
(3) flexible rad hoses (or ones that match the bend)
Spacer, (I made mine, and I think Turbo Tim makes them too) spacer has 2 outlets, one that matches the temp sensor, and the other is a 1/4 pipe threading
1/4" pipe thread to 5/8" pipe thread "reducer"
insert a bolt in the opening on the reused thermostat upper housing. I drilled and tapped the flat surface to insert the secondary temp sensor (green)
some wire to relocate the front temp sensor.
freeze plug ( I made a plate to make it look pretty) haha
5/8" pipe thread to 1/4" barb
hose 5/8" with a 90* in it. 3/8 hose if you dont already have extra from your turbo.

re-used:
rad hose and metal hose from the bottom outlet of the rad. relocated to the top input of the rad going straight down under the intake mani
heater core 5/8 hose
1.6L tstat upper housing
temp sensors
heater core(acts as a secondary rad for the turbo) WORKS GREAT!
some other little pieces like clamps.

reroute goes like this....
out rad into the motor, pipe fitting to go to turbo
turbo water outlet goes to heater core
engine water passes straight through the motor and through a spacer where it meets with
the water from the heater goes through the spacer and back into the system
spacer has a pipe reducer and the grey temp sensor
1.6L tstat upper housing is attached with longer bolts and is drilled to fit the green temp sensor
flex hose or a fitted hose with a 90* built in
Turbo Tim tstat housing drilled with a fitting.
the return line from the throttle body can be fished through the intake manifold for a perfect fit to the tstat housing
flex hose or fitted hose with a 45* built in
mated to the reused metal and rad hose

FINISHED!!!!

You retain the heater core and provide extra cooling for that turbo water!
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Old 06-04-2008, 10:33 AM   #6
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Looks decent, good job, I need to get off my *** and do mine already.
I am liking the spacer of yours, you may want to talk your dad into making a few and posting them for sale. Why not?
Q-why didn't you use the 1.8 t-stat housing on the back as well?
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Old 06-04-2008, 12:22 PM   #7
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I had an 1.8 Tstat housing for my 1.6 head, but the way outlet fits its either point up or down. With the 1.6 is Left or Right.
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Old 06-04-2008, 01:44 PM   #8
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1.6L housing in the back of the head, originally off the front tstat housing
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Old 06-04-2008, 05:45 PM   #9
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i like the idea of using the 1.8 thermostat housing outlet on the water pump inlet and the 1.6 t-stat housing at the rear.
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Old 06-04-2008, 06:05 PM   #10
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Paul, what were you using on the back of the head? A 1.8 housing?
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Old 06-04-2008, 06:10 PM   #11
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no, the 1.6. i was joking. he used exactly what i did plus the Turbo Tim t-stat housing.



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Old 06-04-2008, 06:15 PM   #12
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If I have COPs and I have the coil packs and bracket out of the way, I should be able to use the 1.8 housing and go cold side without any issues? Any input.
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Old 06-04-2008, 06:20 PM   #13
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i forget what the back of a 94-97 head looks like but i remember there being **** in the way on the 99 head. temp sensor, oil cooler outlet line
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Old 06-05-2008, 03:04 AM   #14
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All I know was I had to trim my coil bracket. And yes I based my re-route off of Paul's. But I went cold side and retained the heater core using the turbo water return line as the feed. So mine is a little different
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Old 06-05-2008, 01:13 PM   #15
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I think Paul set the standard here by using the 1.8 housing as a feed for the WP, I love that!!!!x12
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Old 06-05-2008, 01:45 PM   #16
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Is that going to accommodate A/C and P/S????
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Old 06-05-2008, 02:16 PM   #17
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I like the idea of using the 1.8 thermostat housing on the WP inlet, but it looks like it will interfere with AC/PS belt. If that's the case I wonder if the 1.6 housing pointing straight out the front might work.
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Old 06-06-2008, 02:24 AM   #18
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I removed the powersteering box before that, Sorry man. I dont have PS or AC. If you left the PS I think you may even have to retain the mixing mani or have a straight shot to the back of the motor (i think... mind you this is from memory). Just so happens the 1.8 is perfect for me because I have a water cooled turbo and the feed was right there for me, and I used the return line as my heater feed. If you havent dropped your power steering, let me be the first to recomend it.
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Old 06-16-2013, 05:57 PM   #19
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i was impressed with your skills...CNC machining, then i saw this:

WTF IS THIS?

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Old 06-16-2013, 07:40 PM   #20
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That my friend, is a post from 2008.
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