Many owners agree that the original 480x285mm radiator is not sufficient for hot climates. Especially in the height of the summer, there are some situations that limits the car's performance because of overheating.

Such examples are:

- Hill climbs over 50Km/h. If the car can handle the same hill when outside temp is 20ºC and you can't climb the same hill when temp is 30ºC because the temp gauge is constantly rising and you decelerate to 25-30Km/h to prevent overheating.

- Driving on a fast road, the speed is over 90Km/h and the the temp gauge is slowly rising. You can't keep the pace. You have to slow down to let the engine cool down.

More importantly the expectation of overheating makes you nervous.

 

Scope of this upgrade: When there is enough natural air flow and the engine is not cooling down.

If you have problem with traffic jam overheating. That is usually a problem with inadequate fan performance. Especially the 4 blade old Skoda fan: https://pasteboard.co/KeVy0sf.jpg seems to be insufficient in hot climate summer time. Felicia full fan cover (6U0121207) with 6 blade tropical fan (165959455G) will do wonders.

 

My aim here is:

- Create more thermal headroom so driving in summer is less worrisome.

- Being able to install a standard thermostat and fan switch so the engine can run as its designed temperatures for better efficiency.

- Lessen the burden on the radiator fan so it won't die sooner than expected.

- Better cooling capacity for sustainable high load scenarios.

 

Objectives:

- Keep it simple. Whole system could be mounted easily without cutting, drilling or welding.

- Use as fewer parts as you can.

- Keep it cheap.

- Use standard and worldwide available common parts.

- Make it sturdy yet, flexible enough to accommodate engine vibrations.

 

Parts list:

- Skoda Felicia 1.6 radiator: 6U0121253. Active cooling area: 590x285mm. (Perfect fit to the standard mounting points of the old radiator.)

- Felicia full fan cover 6U0121207 with a six blade fan 165959455G if you don't already have it installed on the smaller 1.3 radiator.

- Renault Clio/Kangoo cooling system pipe: 7700869985. (Only a little modification required)

- Lada Niva 1700 upper radiator hose: 21213130302500

- 2x Heavy Duty Pipe Clamp (Bracket Type) With Rubber Profile. Size 3/4". Like this one: https://pasteboard.co/KeVOuuC.png

- 3/4" Hose joiner. Like this: https://pasteboard.co/KeVPidg.jpg

- 10cm long 3/4" car coolant compatible hose.

- 2x 20-30mm hose clamp.

- 2x 28-48mm hose clamp.

- 2x 6x15 bolts. Allen head or hexagon head recommended.

- 2x 6.4x12 washers.

- 2x 6.4x20 washers.

- 2x 6.4 split lock washer.

- 2x M6 nuts.

- Depending on your cable setup, cables and/or connectors may be required for thermal switch relocation.

 

How to install:

- You start by removing battery connections. Important for safety! (I prefer removing both. Negative first, positive second. Installation is reverse order.)

- Drain the coolant. Don't let it run away even if you are not planning to use it again. It's poisonous. Dispose with responsibility.

- Remove all radiator hoses and electrical connections to the fan. If you have anything else attached to radiator/fan assembly for structural support, remove them too. Fan shroud bolts on the bottom side and they are hard to remove so you will have to remove radiator and fan assembly together in one move. Have a helper to hold cables and hoses out of your way so they won't be damaged. Especially watch for the upper radiator hose. Don't scratch it with sharp metal edges. Watch for where you are holding the radiator. Thin radiator fins are VERY prone to bend. This will reduce efficiency of the radiator.

You will see two L shaped metal brackets on top of the radiator. When you remove those two bolts, whole assembly will be ready to pickup.

 

Radiator removed: https://pasteboard.co/KeWe6Jr.jpg

Check for your rubber bushings. If they are worn or missing, replace them.

 

- There is a plastic air deflector at the right side. Installed from factory as a place holder for future upgrades like a larger radiator or an additional radiator for oil cooler. We need that extra space right now for our larger radiator. So it needs to be removed.

Plastic wind deflector: https://pasteboard.co/KeWftsS.jpg

It's secured in its place by plastic pins. One pin is easily accessible through engine bay but other pin is only accessible if you remove the right headlight. Old plastics become brittle so don't worry if you break one of the pins like me. If there will be need arises to return to original setup again. Pin location can be drilled and a seperate plastic pin can be used.

Air deflector removed: https://pasteboard.co/KeWkFv6.jpg

Notice the red arrows pointing the holes in the front frame above. There are holding clamps for headlight height adjustment hose. We will use those holes for our pipe clamps.

 

- Before installing the Renault pipe, preparation is needed.

We won't need or want this bracket on this side of the pipe so it needs to be gone. https://pasteboard.co/KeWmYju.jpg

It's edge welded. So only a little cut will set it free. Be careful not to damage the pipe.

Bracket removed: https://pasteboard.co/KeWomEr.jpg

This is the place where our hose clamp will clamp so smooth out the surface. I also applied some nail enamel to cover the sanded area. https://pasteboard.co/KeWqOOY.jpg

- Now the unexpected and annoying part with the pipe: https://pasteboard.co/KeWrnGi.jpg

I've discovered this after cutting that bracket so couldn't return it. It seems to be a lazy manufacturing attempt. Check yours before buying.

I've did my best to correct it. https://pasteboard.co/KeWuosA.jpg

You are looking inside of a 30mm pipe.

 

- Mount the Renault pipe using pipe clamps:

https://pasteboard.co/KeWA8se.jpg

https://pasteboard.co/KeWB6wE.jpg

https://pasteboard.co/KeWBXqs.jpg

All connections are loose at this stage. You will need to adjust whole assembly with the hoses attached.

Insert bolts from front with the order: Bolt, lock washer, small washer, car frame, pipe clamp, large washer, nut. Luckily you won't have to remove front bumper or anything to reach the bolts from front. You can access them from bumper grilles.

https://pasteboard.co/KeWG46c.jpg

Access to the heads is not straight though. You will need a long flexible extender. I used two screwdriver magnetic bit extensions.

https://pasteboard.co/KeWH2uX.jpg

When used multiple, they give you a little flex but I recommend flexible extensions.

 

- Remove fan and its shroud from old radiator and bolt them on the new large one.

- Install the radiator fan assembly to its new place. Watch for rubber bushing spacing below the radiator. You must feel them to align properly with the radiator feet. Screw in the two bolts holding the radiator from top.

Radiator installed in its place:

https://pasteboard.co/KeWM7u3.jpg

- Install top hose:

https://pasteboard.co/KeWN0m8.jpg

- Now the Lada niva hose comes to the rescue:

https://pasteboard.co/KeXihyW.jpg

You can see the parts marked as A,B and C. Use the end with sharp 90º turn (marked as A) between radiator exit an Renault pipe entry. Use the other end (marked as B ) between Renault pipe exit and engine entry pipe. The tricky part here is, carefully adjust the lengths of the hoses before cutting. If unsure, cut longer. Adjust whole assembly at this point.

Important note: What is the C part for? That's for noise canceling. If you have a bottom splash shield like my car has, the chances are you will end up with a terrible rattling sound after finishing the project. You will have to drain the coolant again and insert that hose part before inserting part B. Part C should be inserted to the bottom of the engine entry pipe so it will fit between splash shield and metal pipe.

https://pasteboard.co/KeXo7vg.jpg

https://pasteboard.co/KeXovQH.jpg

https://pasteboard.co/KeXprBT.jpg

Part B and Part C marked:

https://pasteboard.co/KeXrLEK.jpg

 

- You haven't tighten the pipe clamps yet. Don't forget them. When adjusting the spacing of the Renault pipe with the main hose connections, tighten the pipe clamps when your setup is satisfactory.

https://pasteboard.co/KeXtZO8.jpg

https://pasteboard.co/KeXuP94.jpg

https://pasteboard.co/KeXvegp.jpg

 

- Coolant tank connection is easy but I made a mistake here too. 1.3 radiator coolant tank entry point diameter is 20mm but coolant tank exit diameter is 25mm ! I bought 50cm 3/4" coolant spec hose but couldn't fit it to the tank exit. It won't stretch that much. I didn't know tank exit diameter was different. So either use one piece 1" coolant hose or do it like me and use a hose joiner at the Renault pipe secondary entry point. 1" coolant hoses are harder to bend so I preferred this way. I didn't cut the original tank hose just a small extension at the end. So use the 10cm 3/4" hose here and join the hoses together with 3/4 hose joiner.

https://pasteboard.co/KeXBGYf.jpg

 

- Don't forget about the thermal switch and its cables. I use PTFE thread sealing tape on thermal switch rather than torquing too much.

- Double check every connection. Every hose clamp. Don't forget the coolant draining plug. I use PTFE tape for that too.

- Fill your coolant slowly. Check for any leak. Bleed the system properly.

- Connect the battery.

- Fire up the engine and test stationary for any leak. Check temp gauge regularly. Place your hand on the top radiator hose and wait for thermostat opening. You will feel the heat when thermostat opens. From that moment check by touching different places of the radiator and the bottom hoses and pipes you have built. Both for feeling the heat and any leakages. If anything seems suspicious stop and fix.

 

Radiator dimensions for comparison:

https://pasteboard.co/KeXJjNX.jpg

https://pasteboard.co/KeXKIAf.png

https://pasteboard.co/KeXLhHxC.jpg

 

Initial test results shows it is noticeably better at the long hill I have to climb every day but how much? I'm planning to record a similar video like video before with similar conditions to compare the the results.

I hope you find this post useful.

!WOW!

WHEN I SAID YOU ARE MECHANICALLY MINDED THATS WHAT I MEANT 
This mod I wanted to do to my own felly for some time,

though I would have done it differently the working principle is correct water reservoir connected to the suction side of the pump (lower rad hose)

Absolutely perfect.

Astonishing job (now we want test results)

On 08/08/2021 at 20:26, R_Blue said:

I use PTFE tape for that too

Just use the OE crush washer

14 hours ago, Thefeliciahacker said:

!WOW!

WHEN I SAID YOU ARE MECHANICALLY MINDED THATS WHAT I MEANT 
This mod I wanted to do to my own felly for some time,

though I would have done it differently the working principle is correct water reservoir connected to the suction side of the pump (lower rad hose)

Absolutely perfect.

Astonishing job (now we want test results)

Just use the OE crush washer

Thank you.

I'd love to see your modification too.

 

This is a budget oriented mod. With a more relaxed budget, better solutions are possible.

This one is a fine example:

https://www.youtube.com/watch?v=JMrMyE2V9tI

 

I almost forget how much did it cost?

Radiator= $45

Clio pipe= $6

Lada Niva hose= $3.5

All other minor parts in the list= $5

I'm lucky to have the Felicia fan and fan shroud came pre-installed with the car so I didn't pay for them.

 

I'll record another test video as soon as I can.

5 hours ago, R_Blue said:

This one is a fine example:

https://www.youtube.com/watch?v=JMrMyE2V9tI

thats is exaclty how i would approach but silicone is not great for long lengths and coolant

On 10/08/2021 at 20:03, Thefeliciahacker said:

thats is exaclty how i would approach but silicone is not great for long lengths and coolant

Wow, I didn't know that. I'm glad I stayed away from silicone hoses.

 

New test video is ready.

Please check:

Škoda Forman (Favorit Estate) Test On A Hot Summer Day

 

 

 

On 10/08/2021 at 20:03, Thefeliciahacker said:

silicone is not great for long lengths and coolant

 

Why?

So we stick to the original hoses or we buy aftermarket hoses (from italy for example) for temperatures at least 120 'C?

 

On 08/08/2021 at 20:26, R_Blue said:

I hope you find this post useful.

 

Unfortunately the links of the photos are not working.

On 10/08/2021 at 18:03, Thefeliciahacker said:

but silicone is not great for long lengths and coolant

That is new to me.  For long lengths it might depend on the quality of the hose, I have had three and four ply silicone hoses but thinner walled hoses could be supported and secured with clips.

 

When rubber hoses were of very poor to abysmal quality for my "classic" MG I fitted a full set of silicone cooling/heating hoses and unfortunately most of them were disconnected and reconnected a good number of times for various work on the car and that was over 14 years and they are still on the car now and look in good condition and internally they must be good or they would not have been kept with the last engine removal last year.

 

Classic Silicone Hoses (a very small company unless it has changed) - they do not make a Favorit/Foreman set but I am sure they could. - http://classicsiliconehoses.uk/product-specification/

 

They do a set for "Octavia Felicia"(?) and they offer different finishes and colours. - http://classicsiliconehoses.uk/product-options/

 

I am nothing more than a satisfied customer, no connection or profit for me from promoting them.

 

 

 

 

2 hours ago, nta16 said:

 

 

 

 

 

 

Only the right hose with 45' degrees can use it in Felicia (you have to cut it), connects the throttle cover with the air box and it's 65mm diameter.

 

Fair enough, I did wonder, perhaps it is mislabelled I would have thought they were made by customer request.

 

Edited 10 June, 20232 yr by nta16
missing word

So, the question remains:

 

On 10/08/2021 at 20:03, Thefeliciahacker said:

silicone is not great for long lengths and coolant

 

 

 

On 09/06/2023 at 12:18, D.FYLAKTOS said:

Why?

Its called permeation, you will simply be loosing coolant (the water infact out of the coolant mixture) all the time, good for the track, good for high temps good for high pressures but not a set it and forget is solution. 

It has approx 1000% to1500% higher permeation rate than our beloved epdm hoses.

In a year of driving you can loose up to a litre.

Imagine that, that would drive me nuts

10 hours ago, Thefeliciahacker said:

In a year of driving you can loose up to a litre.

 

😲

12 hours ago, Thefeliciahacker said:

In a year of driving you can loose up to a litre.

That was not my experience in 14 years of using the silicone hoses I had and the car only held about 4 litres of coolant in the cooling and heating system and I checked the coolant level regularly and used a coolant renowned for finding any small weeps or leaks.  The pressure cap (old metal type) was rated at 15 psi and car was not running at high coolant temperatures.

 

As always with percentage figures you have to ask 1,000% or 1,500% percent of what as it could be life changing or barely, or not, perceptible, old or poorly made rubber hoses can be poupous (if poupous is not the correct technical word then replace it with the one that is as I am sure you know what I mean).

 

Quote

Skoda Felicia 1.6 radiator

Renault Clio/Kangoo cooling system pipe (Only a little modification required)

Lada Niva 1700 upper radiator hose

 

The stock 1.3 hoses won't fit in the new 1.6 radiator plastic sockets?

2 hours ago, D.FYLAKTOS said:

The stock 1.3 hoses won't fit in the new 1.6 radiator plastic sockets?

 

The 1.6 radiator doesn't have outlet for the expansion tank and outlet to the pump is on the same side as the inlet.

5 hours ago, Papez said:

 

The 1.6 radiator doesn't have outlet for the expansion tank and outlet to the pump is on the same side as the inlet.

 

 

 

 

In the 2nd photo is more visible.

On 09/06/2023 at 12:18, D.FYLAKTOS said:

Unfortunately the links of the photos are not working.

I'll check if I stored them somewhere. If not, I can take new photos. I'm still using the system. No problems so far. This is the best upgrade ever.

@R_Blue hi mate, I’m suffering with my 1.6 Felicia overheating even over here in the UK at 8 degrees. While searching for answers and solutions I’ve come across your comprehensive write up and would like to understand what you did better. When I try to open the pictures all I get is “image not found” messages for all pictures. Is it possible to share the pictures again or tell me how I can get to see them elsewhere where?

regards Rob