Cooling system.

[joosep]

I got my first wasserboxer....actually 2 of them. bouth 2,1 82kw

Im scared of water pipes.....so many of them. and few of them are missing and another ones are awfully rusted.
Could I make it somehow with less pipes and what are nessesary and what not.

My plan is to use it on winter car.....quick warming up is not the target....I would use only 1 big radiator and some air channels in to the car.

Thank you.

[AMBROSIA]

The earlier style cooling system is much simpler and can be retro fitted.
Sadly those rusted pipes would be needed for either style.
You would need to source a thermostat body and also run an external oil cooler as the 2.1 sandwich plate is not compatible.

[fastback]

if you keep the stock cooling system (included the "bleed/small bypass circuit containing all the ~8mm hoses and the tube), it is easy too bleed and get the air out of the system.
Some people have not used the "bleed circuit" with success , but 2 of them i have got ffedback from says it has been more tricky too bleed.

[joosep]

I´m not scared of the bleed problems. Would like to get it as clean as it could be. I would remove all not nessesary stuff. Getting it warm quickly is not my target.
Are there any simple diagram of hoses or explenations what I have to keep.?
all the rubber hoses have been cut off and I have no idea what to connect

[westypoo]

Look at my build thread. It has diagams of the hoses. Ive simplflied my cooling as well.

[joosep]

I would lik to know how it works, then I could simplify it myself

But I´m a bit confused when I look these 2 pics:





I don´t get how the water comes to the case. Does it comes from 1 side to another or it comes threw pump to bouth sides.

I mean the arrows on the left side of the case.

[buildabiggerboxer]

Joosep. the diagrams give the right flow paths, my set up is similar to the top diagram with the electric pump, but the pump shown is not in the best place, it should be opposite where shown near the t'stat housing so it pumps water already cooled by the rad', you could also ditch the 'stat housing to simplify the system further as you say quick warm up is not your priority, these engines warm very quickly even with no 'stat. you would join the red pipe from the rad to the bypass tube in the pic above, and delete all the other by pass pipes and the trans cooler pipes, heater is up to you.
water does not go one side to the other internally, only across the pipe shown to get to the r/h side cylinders, its cool at this point, its pumped round the cyls to the heads heating up as it goes, it EXITS both heads at the pipes you will see on each corner of the head castings one large, one smaller bolt on, on each head, by now its HOT.
you can delete the bleeder ring and pair up the two head exit pipes on each side to feed as two larger pipes into your single main hot side feed pipe to the radiator/s, or run them thro coolers/ intercoolers, whatever you like, then into the larger flow pipe to the front rad, my flow and return rad pipes are 32mm. you will need adapter pipes with tees to feed the heads into the 32mm flow pipe near the engine somewhere, then flow up to the front rad.
we can buy the new metal water pipes here in the uk, but i make my own water exit pipes for the heads, the ones that would as stock go to the bleeder ring, their usually rotten, just steel plate and 8mm copper pipe brazed in as required. get cracking now then.

[joosep]

It´s hard to understand it 100% because of my language barrier but I got that simplified system without thermostat and internar cooler and other stuff would be like:

1. radiator pipe comes to pump (Threw bypass metal tube)
2. radiator pipe would go to connected heads over the tranny (on the left I should remove just the thermostat housing)


Then pump gets the cold water from radiator and pushes it over cylinders.....then to the heads....(directly to left and threw pipe to right) and after leaving head they should get together to the radiator.

But why are the arrows in upper pic oppisite way in the left side of the engine?
And why has the right side of the engine more volume? Because of the pump location it pumps cooler and more to the left?

Thank you. It was big help for me because I have no car to look for the pipes and got 2 engines without hoses and pipes.

[buildabiggerboxer]

joosep, your getting it now, the l.h flow arrows in the top pic are just wrong, the lower one is better, the volume is the same in the real engine on both sides, water flow is always cool in low, hot out high, but of course our engine is flat, but you know what i mean, in , cold, on the block/pump, out at the heads, hot, then you cant go wrong, you will need to consider a header tank to fill and bleed the system, you can take a small dia' tee off the left head, up to the header and feed it back in to the pump cold side, the replacement 2.1 pumps have a fitting on them suitable, it originally was the return from the oil filter/ heat exchanger water supply.