new hydraulic lifters in place, £19 from ebay

fast road cam in, (was free kind of )

oil splash sheild then rocker cover

and now i'm at the same stage i was before i took the crossflow head off

nice simple belt run (with diesel tensioner) should be nice an easy to replace in the future, won't even need to drop it off the engine mount to get the belt in

Ah; I remember timing belt runs like that!

becuase the diesel tensioner has a different offset i need to make the spacer i mentioned previously so that is correctly aligned with the pulleys, in the pic you can see the 'gap'

note: before anybody says it, this is an old belt that i'm using to avoid the new one being damaged whilst i'm messing about

i need to figure out where all the coolant hoses go, i think there are a few outlets/unions that won't be used due to the fact that i'm using a mismatching engine block and cylinder head... answers on a postcard..

ok here goes, i'm not that hot on cooling system theory so i'm making this up as i go

A: radiator bottom hose (which will have to pass along under the coil pack and oil filter)

B: to the bottom of the expansion tank, might have to shorten this a bit to get enough clearance to get hose on

C: thermostat housing (and coolant temperature sensor), iirc they have a small take-off which goes to the top of the expansion tank too but if not i'll have to use one of these pictured below from the top radiator hose with the small take-off going to the expansion tank

A: oil cooler return, i'm not using the oil cooler so i can block this off

B: no idea where that should go but i don't need it so it will be blocked

C: return from heater matrix

D: plastic housing, heater matrix feed, also there is an alternative housing for this which has the coolant temperature sensor in on the inline mounted engines (audi 100 etc) iirc..

i might shorten that whole black pipe to a short stub just behind the coilpack so it's a bit more tidy..

any comments of cooling system greatfully recieved, obviously the expansion tank needs to be above the water level in he cylinder head etc

Reply to #356 - I'm sure that A and C are right but think B as an expansion feed might feed off the radiator rather than the block? Which suggests B might be for the heater system?

i'm trying to visualize this engine when it's in it's natural home (mk4 golf) the expansion tank is on the left near the front iirc, so it would make more sense for B to go to the bottom of the the expansion tank, the steel pipe in post 357 is just a continuation of the pipe in 356, i'm pretty certain that it makes up a common return path for all the cooling system components except the radiator which has it's own return via that dogleg plastic pipe in 356.

are you planning to use the standard felicia radiator/fan combo to cool the beast ?

yeah

It might be under-cooled then. Try it, but try and have a back-up plan in place too.

Another option includes the substitution of the thermostat for one that operates at different temperatures. A low temp fan switch shouldn't be too difficult to get hold of either.

i reckon the radiator is more then capable for the job tbh

ok here goes, i'm not that hot on cooling system theory so i'm making this up as i go

A: radiator bottom hose (which will have to pass along under the coil pack and oil filter)

C: thermostat housing (and coolant temperature sensor)

i was wrong, A: is the thermostat housing, but C: does go to the top of the radiator and the plastic housing contains the coolant sensor

not very interesting... made the spacers i needed

had a really unfruitful day, been to 5 different breakers yards and i cant find the water outlet housings i need so it looks like i'm going to have to buy them new

The seaward repair centre that assesses accident damage had a felly going their way yesterday so it might be worth giving them a call to see if it's a w/off and if it is can you nick the bits

thanks for the 'eyes open' but it's a golf gti, or a diesel that i need to get the bits from

Tom, you could plumb in an old heater matrix into to system to help the cooling

if needed

Surely if it becomes an issue you just put a fan that pushed more air on the back of the rad?

Obviously this only works to a point and then you have to go up a size in radiators.

Or you could louvre the bonnet ALA RS turbo but with slides underneath the louvres closed in cold weather and open them to let heat out in hot weather rather than trap it in the engine bay:):)

Or get really trick and have temperature controlled cables for them like the ones used on deisel pumps and fix the sensors near the front of the bonnet near the rad:thumbup::thumbup:

Or just keep the heater fan running

seriously, i think the standard felicia radiator is more than capable, it's only the routing/locations of the coolant hoses themselves that i'm puzzling over

Just joking:rofl::rofl:

The standard set up should be pretty adequate its not like your filling up the engine bay with a 16v head and reducing air flow around the engine too much over a normal 1600.

Sorry can't help with pipe routing as not familiar enough with VW stuff.

Just hot and cold to rad with thermostat on head outlet normally, take off and return to head for heater, expansion tank normally goes to bottom of rad or lower hose with bleed pipe from thermostat housing to expansion tank, nothing you already know i'm sure. But you don't need much else:)

been doing a bit of digging around and it seems that the plastic water system unions/flanges ae only about £10 each new from vw, a lot cheaper than i thought they'd be. off to german and swedish tomorrow again methinks to see if they stock them