Conversion Specific Coolant Hoses:2.0l Turbo.

[sonofsam 5]

Hey Mates.

 

Some of you might know that I mentioned having a set of Silicone coolant Hoses made up for my 205 Turbo.

Well the time has come for me to start putting some design's and plans together

 

Below is the plan that I worked to when modifying my existing rubber hoses.(Courtesy of Alex_G)Which entails quite a few custom T-Pieces and even Tri-Pieces all involving quite a few hoseclips wich I am aiming to cut down on.As this is the only part of my conversion Im not 100% happy with.No leaks,(except for my Heater Matrix...thats another story) but in my quest for perfection everything has to be just 'so'.

 

So if any Members have used a different scenario to this, then I would like to hear from you:)

A few of you have said how easy it was to mod the water hoses, but in all honesty I found it a bit of a pig!

 

I used to work as a Rubber hose builder so am quite familar with the techniques used in manufacturing items like these and will be contacting www.sfsperformance.co.uk in due time to discuss our requirements.

(Please exscuse the slightly dented Oil filter )

 

Mainly going to be concentrating on the top hose(Thermostat to Radiator) to start with as this is were most of the slightly awkward joins begins.Then onto the rear hose(Expansion tank>Heater Matrix>Water distribution block)

 

So the main crux of this post being.Any Members on here done it any different to said plan ( simplified )

Anyone with a bare block sitting in their Garage ( I know there are a few:) like to measure some pipe O.D's for me.Thermostat and water block would be nice:D

Any areas that could be improved on and if people would be intersted in a set and possible group buy.

 

Thanks

Sam.

[welshpug 1,663]

one thing that would make life a hell of a lot easier would be to ditch the oil to water cooler in favour of the earlier oil to air type, this would then allow you to use a plain hose like samco produce for the top hose.

 

the larger on in this picture actually

 

 

slightly confused as to some of the routing but I think i've guessed what youre trying to achieve

Edited November 6, 2006 by welshpug

[welshpug 1,663]

right, heres a quick scetchy mock up of how I would go about it

 

 

basically all the hoses are standard bar the two that go to the turbo, and the longer one might even be usable if a reducer is fitted.

 

so going about it that way would mean 2 custom hoses and the rest would be standard samco (or other) shaped hoses, and there wouldnt be a single hose with a joiner or joint in it

 

hope that helps!!

Edited November 6, 2006 by welshpug

[sonofsam 5]

Yeah helps.Thanks for that

 

So can I just plumb in said Oil to air type cooler to the existing ports?

Got a feeling the diameter is different on the port on the back of the 'stat, but will check that out, unless someone has it to hand

[welshpug 1,663]

no, you'll need to swap the current coolant thingy for an oil takeoff unit.

 

either obtain one off another 205 or fit a mocal oil cooler kit from Rally design (which IIRC does have a thermostat to aid warmup, thich the std unit does not if i'm corrrect)

[tom_m 0]

the oil flowing past the turbo containing 800 deg C exhaust gases is the only warmer you'll need for the oil didtch the oil warmer and get a wide open mocal air/oil cooler, you can always wrap it in winter if it manages to over cool

[sonofsam 5]

Sweet.That sounds like a plan Man.Do you know wich ones fit Tom?

 

Off to bag me some more Samco aswell

[inferno 1]

AIR - OIL and water to oil coolers are interchangable

Sam in my original attemps to reduce water pipewprk i used a 318 bmw rad with built in header. this actually worked vey well after bleeding it properly with a higher temporary header tank. water should go to the turbo from the bottom pipe and then into the top hose from the other side.

 

Keeping the lenth or pipe and volume of water down under the bonnet could only be an advantage as itll lower temps under there and improve cooling. Im starting my next conversion next weekend now, so maybe could put my hoses plan to you in a few weeks

 

the later turbo engine has a solid water pipe running behind the cam belt cover, are u using this? its very close to the turbo so imo this would be worth keeping/rerouting. My finished zx turbo water and induction pipe work was all very short and tidy, even if i say so myself

 

i would like to see t16 pipework on paper though as im planning to use a t16 cooler this time round, so my water pipes would be better adapted from those possibly.

 

ps sweet color coding there with the black and silver;)

[tom_m 0]

Sweet.That sounds like a plan Man.Do you know wich ones fit Tom?

 

Off to bag me some more Samco aswell

 

the 1.9 gti one will fit, but bag yourself a mocal kit (bigger the better;)) with an sp1 type adapter and that'll fit too

[welshpug 1,663]

clicky for mocal!

 

clicky for samco!

 

Rally design can't be faulted for theis service, knowledge and sped is second to none and theyre probably thr cheapest for samco anywhere

 

If youre going to go about it as I described a kit for an 89 non pas and oil to air cooler is the kit to ask for, cant remember the code for it but the guys I spoke to knew straight away, red and blue are the two colours they stock too

 

youll need the sandwitch plate and fitting kit, and most people go for the 13 row cooler as its the closest to the size of the o.e unit. another thing that'd be a good idea to add to the oil cooler setup is a stat.

[tom_m 0]

youll need the sandwitch plate and fitting kit, and most people go for the 13 row cooler as its the closest to the size of the o.e unit. another thing that'd be a good idea to add to the oil cooler setup is a stat.

 

most people got for the 13 row on NA 2lt engines, i'm going for a 16 row on the turbo, if you're pushing hard its going to be a huge source of heat

[Bam 0]

yeah...

 

i have nearly the same problem, i go the same way but: (like sonofan draft)

i'm looking for good solution to connect waterreturn from turbo back to watercycle.

 

have 2 ideas:

 

1.)i connect waterrertun with a t-piece to thermo housing (1 tube goes back to expansionstank) like draft

2.)i connecet under...the expansiontank a t-piece and connect there waterreturn from turbo.

 

what do you think?!

 

cheers

mik

[sonofsam 5]

most people got for the 13 row on NA 2lt engines, i'm going for a 16 row on the turbo, if you're pushing hard its going to be a huge source of heat

 

Cheers for all the ponters so far Dude's .Looks like my intercooler is going to get a friend to keep it company up front:D

[Sam 4]

Is it advisable to run water cooling on a turbo? My turbo has the connections for it, guess its a good idea to use them?

[Bam 0]

@sam

i think it will not hurt .

 

@other

*push topic*

any ideas?

 

mik

[Bam 0]

here is a picture...

will this work?

[sonofsam 5]

Im not 100% sure on how im going to set mine up yet.

[tom_m 0]

Is it advisable to run water cooling on a turbo? My turbo has the connections for it, guess its a good idea to use them?

 

like bam says can't hurt, its there for a reason at the end of the day

[sonofsam 5]

water should go to the turbo from the bottom pipe and then into the top hose from the other side.

 

Is that 'Top hose' as in Thermostat>Radiator?And does it still need a connection to the expansion tank if not?

 

Yes have that Metal pipe still btw, will be keeping that but maybe a reroute as you say

[Henry Yorke 269 3 Cars]

I was very paranoid about oil temp on my CTI Turbo as the original 1.9 DFZ engine did not have an oil cooler of any form! I still don't and the oil temp does not rise above the 2nd notch even when pushed hard. I did fit an Mi16 sump as these cool much better than any standard pug oil cooler due to the fins and alloy heat dissapation properties. I have also plumbed in the water cooling on the turbo as it is there for a reason and stops your oil getting hot! An alloy rad also

 

What you have to be careful of is the water return from the turbo as when the car is turned off after a run, the turbo is still hot and the water is static in it, therefore acts like a big kettle. This means the water needs to be able to bubble back to somewhere without presurising the system excessively. Therefore my turbo water outlet goes back to my header tank to allow for this expansion and you can hear it glugging back when parked in the garage after a spin.

[James_R 3]

The ford boys tend to remove the water cooling from the turbos when they go higher power, not saying it's right or wrong, but that's that they do.

 

Personally I'd dump it and go for a potent oil cooler set up and run good oil, and as tom sasys a huge mocal I ran a 13row wide type cooler, and at the ring was fine, at combe started getting warmer than I wanted, and at anglesea was getting on the too hot side of the gauge. This was an Mi steel sump though, I'm swapping to an alloy sump on the new engine so hopefully won't be such an issue.

[sonofsam 5]

So basically the water return from the Turbo should have feeds to both, back into the system and to the exp[ansion tank?As per first picture I posted.

[sonofsam 5]

Well i decided to go for this: A few T-pieces still remain , but I managed to score some cheap'ish 205 specific samco's to play around with:D

 

Stainless Steel/Alumium top water pipe in the production line.Not sure wich material is best?

[Bam 0]

hi,

 

after few test...

i think this would be best

[Gentrix 2 1 Cars]

So you purchased Jan´s Turbo stuff!

 

 

 

 

andi