GT4
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- 8 Nov 2008
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MOD: moved to FAQ
Did this today round a friend's house (a selection of his Snap-On attachments were useful, as was his slightly sloped drive)
Recipe:
WD-40 (always!)
Hartech Low Temp 160oF/71oC thermostat insert
Some spare coolant (I bought 1 litre - although so far I have 0.5L left)
Some distilled water (I bought 1 litre - although so far I have 0.5L left)
Thermostat housing gasket (996.106.326.50)
10x14x1mm crush washer (sealing ring)
Gasket sealer gunk (I used Loctite 5922)
Emory/wet and dry paper and/or scouring pad and/or razor blade
Ideally some disposable gloves so your hands are nice and clean.
Tools:
Clean bucket (or two for good measure)
Funnel
Jug
Old T-shirt or similar clean cloth for coolant filtering
6mm Allen drive (or key)
Medium Flathead Screw driver (or 6mm 1/4drive socket) - for Jubilee clip
10mm Socket
Assorted rachet/extension/universal joint
Trolley jack(s) + wood block to spread weight on sump
Axle stands
Wheel chocks
Method:
1.) Open the engine lid
2.) Chock, jack and axle stand your car (I raised mine by about 20 degrees to staunch coolant flow and hence airlocks and allow access) - If you decide to incline your car too you must chock because the front axle has no handbrake nor gearbox braking (excepting slight C4 wind-up if left in gear)
3.) Spray the penetrating oil (WD-40) on the 3x hardline bolts, 4x thermostat housing bolts and the jubilee clip - leave to penetrate!
4.) Drain coolant using drain plug (6mm Allen drive) and header tank cap for flow control - mine dumped approx 8 litres (or approx 2/3-3/4 bucket) - the plug is to the rear of the sump - most comes out in less than a minute (only remove the header tank cap once the flow seems to be lessening). I left another bucket to collect another 0.5 - 1L over the next 10 mins whilst I had a cup of tea.
5.) To ease access, free the coolant hard line that circles the sump (3x 10mm head bolts).
6.) Loosen the jubilee clip with flathead screwdriver (or 6mm socket) and pull off the rubber pipe to the thermostat housing - be prepared to catch another cup of coolant (or not!)
7.) Now unscrew the 4x 10mm head bolts that holds the housing on.
8.) Gently knock the housing off and peel the old gasket off.
9.) Clean both sealing surfaces - the housing is safe to use any of the emory/wet and dry paper and/or scouring pad and/razor blade methods - just wash afterwards. I would suggest only using the scouring pad on the engine block to minimise debris.
10.) Remove and refit new thermostat insert (I just used an old cap from a spray bottle to compress the spring and rotate to release or fit)
11.) Carefully smear the housing sealing surface with gasket sealer gunk.
12.) Locate the gasket on the housing and apply gasket sealer gunk to the top side of the gasket too.
13.) Refit everything as reversal of removal, fitting new washer to coolant drain plug - LEAVING THE CAR JACKED.
14.) Now the refill: I placed the funnel with (pre-wetted) cloth filter in the coolant header/reservoir tank and just jugged the coolant back into the car.
Try to count the coolant out and back in - I was left with 3L left over on first fill (this represents the air locks present)
15.) Bleeding ("burping") - lift the bleed valve and lock into vertical bleed position.
16.) I carefully ran the engine car still jacked - I idled for a bit then checking no warning lights were on and the temp gauge was working I turned the heater to full temp (and A/C for assisted cooling as the car was stationary and running a partial system fill) - I then held the engine at 4,000 rpm for a minute. I then stopped the engine, lowered the car and and topped up the header tank with about a litre.
17.) On start up the heater started blowing through hot (which is good!). I then went for a drive, watching all the gauges and making sure the heating showed no signs of cold spotting. I checked the header tank again after 5-10 mins of driving - I topped up another 1L.
18.) This is at you own discretion, but given I knew I had only 1L left to refill and the header tank had a decent buffer, I gave the car the beans for another 10 mins (up and down hills and high-G corners and fast acceleration) and after that seemed to burp the airlocks effectively, I topped up with the "Final" 1L .
19.) Drop the bleed valve back to flat.
20.) Let the car cool and check the coolant level immediately before the next few drives and only cease checking when no change in level is evident - top up as necessary.
LIST OF ATTACHED PHOTOS (20160202)
1) Hardline bolts (Note: this is a supplementary support so I don't get squashed - DO NOT JACK HERE):
2) Housing bolts (two hidden by angle) and jubilee clip:
3) Coolant drain plug (actually pictured just before I screwed back in)
4) Coolant (looks green in the bucket, but it is pink :? ):
5) Housing off:
6) Cleaned up housing and the old tstat insert removed:
7) Old tstat thermal rating (83deg vs 71deg - sorry forgot to photograph the new one from the "top" :duh
8) Old tstat insert
9) New tstat insert fitted:
10) Funnel and filter (note some of the crap collected):
Bleed valve (Turbo location for illustration):
Did this today round a friend's house (a selection of his Snap-On attachments were useful, as was his slightly sloped drive)
Recipe:
WD-40 (always!)
Hartech Low Temp 160oF/71oC thermostat insert
Some spare coolant (I bought 1 litre - although so far I have 0.5L left)
Some distilled water (I bought 1 litre - although so far I have 0.5L left)
Thermostat housing gasket (996.106.326.50)
10x14x1mm crush washer (sealing ring)
Gasket sealer gunk (I used Loctite 5922)
Emory/wet and dry paper and/or scouring pad and/or razor blade
Ideally some disposable gloves so your hands are nice and clean.
Tools:
Clean bucket (or two for good measure)
Funnel
Jug
Old T-shirt or similar clean cloth for coolant filtering
6mm Allen drive (or key)
Medium Flathead Screw driver (or 6mm 1/4drive socket) - for Jubilee clip
10mm Socket
Assorted rachet/extension/universal joint
Trolley jack(s) + wood block to spread weight on sump
Axle stands
Wheel chocks
Method:
1.) Open the engine lid
2.) Chock, jack and axle stand your car (I raised mine by about 20 degrees to staunch coolant flow and hence airlocks and allow access) - If you decide to incline your car too you must chock because the front axle has no handbrake nor gearbox braking (excepting slight C4 wind-up if left in gear)
3.) Spray the penetrating oil (WD-40) on the 3x hardline bolts, 4x thermostat housing bolts and the jubilee clip - leave to penetrate!
4.) Drain coolant using drain plug (6mm Allen drive) and header tank cap for flow control - mine dumped approx 8 litres (or approx 2/3-3/4 bucket) - the plug is to the rear of the sump - most comes out in less than a minute (only remove the header tank cap once the flow seems to be lessening). I left another bucket to collect another 0.5 - 1L over the next 10 mins whilst I had a cup of tea.
5.) To ease access, free the coolant hard line that circles the sump (3x 10mm head bolts).
6.) Loosen the jubilee clip with flathead screwdriver (or 6mm socket) and pull off the rubber pipe to the thermostat housing - be prepared to catch another cup of coolant (or not!)
7.) Now unscrew the 4x 10mm head bolts that holds the housing on.
8.) Gently knock the housing off and peel the old gasket off.
9.) Clean both sealing surfaces - the housing is safe to use any of the emory/wet and dry paper and/or scouring pad and/razor blade methods - just wash afterwards. I would suggest only using the scouring pad on the engine block to minimise debris.
10.) Remove and refit new thermostat insert (I just used an old cap from a spray bottle to compress the spring and rotate to release or fit)
11.) Carefully smear the housing sealing surface with gasket sealer gunk.
12.) Locate the gasket on the housing and apply gasket sealer gunk to the top side of the gasket too.
13.) Refit everything as reversal of removal, fitting new washer to coolant drain plug - LEAVING THE CAR JACKED.
14.) Now the refill: I placed the funnel with (pre-wetted) cloth filter in the coolant header/reservoir tank and just jugged the coolant back into the car.
Try to count the coolant out and back in - I was left with 3L left over on first fill (this represents the air locks present)
15.) Bleeding ("burping") - lift the bleed valve and lock into vertical bleed position.
16.) I carefully ran the engine car still jacked - I idled for a bit then checking no warning lights were on and the temp gauge was working I turned the heater to full temp (and A/C for assisted cooling as the car was stationary and running a partial system fill) - I then held the engine at 4,000 rpm for a minute. I then stopped the engine, lowered the car and and topped up the header tank with about a litre.
17.) On start up the heater started blowing through hot (which is good!). I then went for a drive, watching all the gauges and making sure the heating showed no signs of cold spotting. I checked the header tank again after 5-10 mins of driving - I topped up another 1L.
18.) This is at you own discretion, but given I knew I had only 1L left to refill and the header tank had a decent buffer, I gave the car the beans for another 10 mins (up and down hills and high-G corners and fast acceleration) and after that seemed to burp the airlocks effectively, I topped up with the "Final" 1L .
19.) Drop the bleed valve back to flat.
20.) Let the car cool and check the coolant level immediately before the next few drives and only cease checking when no change in level is evident - top up as necessary.
LIST OF ATTACHED PHOTOS (20160202)
1) Hardline bolts (Note: this is a supplementary support so I don't get squashed - DO NOT JACK HERE):
2) Housing bolts (two hidden by angle) and jubilee clip:
3) Coolant drain plug (actually pictured just before I screwed back in)
4) Coolant (looks green in the bucket, but it is pink :? ):
5) Housing off:
6) Cleaned up housing and the old tstat insert removed:
7) Old tstat thermal rating (83deg vs 71deg - sorry forgot to photograph the new one from the "top" :duh
8) Old tstat insert
9) New tstat insert fitted:
10) Funnel and filter (note some of the crap collected):
Bleed valve (Turbo location for illustration):
Attachments
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funnel_large_815.jpg638.3 KB · Views: 287
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newtstat_large_109.jpg642 KB · Views: 287
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oldtstat_large_109.jpg571.7 KB · Views: 287
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old2_large_151.jpg426.5 KB · Views: 287
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onecal_large_939.jpg787.5 KB · Views: 287
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off_large_114.jpg323.5 KB · Views: 287
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buckets_large_109.jpg533 KB · Views: 287
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drain_large_488.jpg306.9 KB · Views: 287
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bolts_large_861.jpg343.9 KB · Views: 287
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hardline_large_184.jpg310 KB · Views: 287