Is my watercooling setup really rare (with pics)?

[sjmtlewy]

Has anyone seen this before - Its an early 1.9DG and I have yet to see any diagrams that match it?

It has the early big rubber hoses that go round from the thermostat to the cooling pipes in one piece and have a little plastic bleeder valve (see pic). On ETKA there are stub hoses off these that go to the heater, but on mine the heater hoses connect to the right-hand cylinder head and to the end of the metal distribution pipe that sits ontop of the engine.

IMG_5761.JPG

Below you can see all the hoses that leave the engine bay. Top two are the big metal radiator pipes. The oversized one with the red writing and the smaller one at the bottom coming off the distribution pipe are to the heater at the front.

IMG_5763.JPG

I'm trying to replace the one with the red writing as its the wrong size. Further down the hose is 16mm ID, but that spigot off the cylinder head looks larger. It must have originally had a specialist hose with an enlarged end.

[Mocki]

thats a early water system, common as a common thing, nothing unusual there.
most of the pipes are now obsolete. i cant see too well from the pic, but if the pipe you need is the one off the head to the heater, its 22mm at the head reducing to 16mm after about 3 iinches and a bend?

[sjmtlewy]

Ok, I was just confused, as on ETKA it has this:

Untitled.jpg

and mine definitely doesn't have those two stub hoses pointing back towards the front

[Cruz]

The stub hoses you refer too are for automatics.

Those pipes and bleed valve are early mk1 version pipes. In 1983 to 1985 they were redesigned to 4 pipes with a larger bleed valve unit in-between like the picture below and the H pipe setup next to the expansion tank was changed (yours H setup is shown in the bottom left corner on the etos/etka page)



Take care of your bleed valve as you haven't a cat in hells chance of finding another.

The heater pipe you require is 251-265-055E which is still available but about £80

I recently changed the other hear pipe which was just bog standard 5/8" heater hose. I couldn't remove the old pipe from under the fuel tank and dropping the tank would have opened another can of worms due to the bolts holding it up being rusted (tank was new 5 years ago). Instead I routed the pipe through the other fuel tank depression to the left (looking at the tank from the back)

I recently got quite a few early hoses from Peter at http://www.wagonbuild.com. He even had the early pipes you have shown the ETKA image of (they like to split where the little hoses join) so he may even have the heater pipe you are after

[sjmtlewy]

Ah - I hadn't counted on it including parts for automatics. Sometime looking at diagrams just confuses things even more.

The old hose must have given out near the engine in the past as there is a replacement section of hose that must be 5mm too large and is clamped down with a jubilee clip. It connects back to the remainder of the original about 30cm behind the engine bay, via an enormous metal joiner.

I think i'll get a straight length of 22mm and some sort of 16mm - 22mm connector (if possible), rather than forking out for the OE solution.

[Cruz]

I am sure the hose starts out as 22mm where it connects to the engine then reduces to 15.8mm all the way to the pipe coming from the heater matrix behind the spare wheel

What about this pipe reducer?

http://cgi.ebay.co.uk/22mm-16mm-SILICON ... 45f4be728a

And this to connect the reducer to the remainder of the 15.8mm heater hose?

http://cgi.ebay.co.uk/16mm-5-8-Straight ... 3efa497e9e

Maybe you may need to use 2 barbed connectors but when I changed the other heater hose I thought it would just be as easy to replace the whole pipe. This way you would only have one connection between the reducer and the remaining 3m of 15.8mm heater hose