jenyus Posted October 29, 2012 Report Share Posted October 29, 2012 81 505 turbo diesel 2.3 in my samurai rock crawler. so the motors been running great but after putting in my new radiator its been overheating really bad and really quickly. theres no thermostat in it right now but it seems like the water just isn't flowing. there's pressure in the system (maybe just from the heat though) but when i grab the upper radiator hose, its hot at the water pump but then it gets cold before it even gets to the radiator. its a newer water pump, only have maybe 30hrs of use on it so far, so i would be surprised if it totally failed on me. any ideas or things to check? Quote Link to comment Share on other sites More sharing options...
Bean Posted October 29, 2012 Report Share Posted October 29, 2012 If it was working great until the new rad I'd suspect an air lock in the system, or something us up with the plumbing. Is this a stock set up for the rad - or do you have a custom rear mount set up or something on it? Any updated pics or vids of the current set up? I'm curious to see it. Rabin Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 29, 2012 Author Report Share Posted October 29, 2012 ill get some pics when i get home tonight. a lot of it is still pretty ghetto rigged. i wanted to get everything in the right place before i got special silicon hoses for it. right now im just running universal flexible hoses on it. radiator is mounted in front of the motor with 2 1500cfm electric fans. okay so let me be more clear, i was having overheating trouble before the new radiator since my old 505 radiator was clogged from the previous owner mixing coolant. BUT it does seem to be overheating even faster with the new radiator than with the old clogged radiator. so since i couldn't find a new direct replacement radiator i bought an 02 vw jetta tdi radiator. its hard to find radiators with both the inlet and outlet on the same side. the only difference between the 2 radiators is the jetta radiator is aluminum, core is about 2in narrower, and has 1.25in inlet and outlet as opposed to the 505 1.75 outlets. do you think thats causing any issues? another difference between the radiators is the 505 radiator had a bleed off (or whatever its called) on the passenger side that went to the reservoir, the vw radiator doesnt have that, so i used the the jetta reservoir which has the large port at the bottom of the reservoir and the small hose at the top. i ran the small hose that comes off the top of the water pump to the reservoir. is this causing pressure to go the wrong way or letting it bleed off or anything? is there anything fancy with the 505 reservoir's ports? could it be air trapped in the system? the new radiator is lower than the top of the water pump but the universal hose that i have does a 270* turn and sits about 2 in above the radiator and about 1in above the water pump, i tried holding down the hose to below both of those to release air but that didn't do anything. it just seems like theres a clog somewhere since the water isn't even flowing. Quote Link to comment Share on other sites More sharing options...
Bean Posted October 29, 2012 Report Share Posted October 29, 2012 I would bet that your hose that arcs above both the motor and the rad is not a good thing. I would also ask where and how high the reservoir is mounted. Hard to offer any more advise without seeing the install better, but from what you provided so far those are my guesses. Once you figure this out, you need to put a thermostat into the engine, it's not a good idea to run without one for a number of reasons. I would actually put one in now as the missing restriction could easily explain these issues as well. Rabin Quote Link to comment Share on other sites More sharing options...
Bean Posted October 29, 2012 Report Share Posted October 29, 2012 Where does the large port on the VW reservoir connect too? Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 30, 2012 Author Report Share Posted October 30, 2012 okay here are some pictures. i need to order a thermostat but i havent had one in for a while and ive done a couple of good wheelin trips with the semi clogged radiator and no thermostat Untitled by jofkeiter, on Flickr\ Untitled by jofkeiter, on Flickr hose from reservoir, a piece that i made myself. Untitled by jofkeiter, on Flickr Untitled by jofkeiter, on Flickr Untitled by jofkeiter, on Flickr Untitled by jofkeiter, on Flickr Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 30, 2012 Author Report Share Posted October 30, 2012 sorry i forgot a pic of the reservoir, but its mounted over the valve cover at the back of the motor, its supposed to be higher than the radiator and water pump, right? Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 30, 2012 Author Report Share Posted October 30, 2012 im still ironing out some issues with the motor, namely the overheating and ive got a pretty bad oil leak that i think is coming from the turbo but im having trouble tracking it down. it looks like its coming out of the flange where it bolts to the exhaust manifold. everything is caked in oil from it so its hard to find the source. i loose about a quarter quart per hour when its running. leaks from passenger side. other than those issues it runs great and works great as a crawler. i havent taken any videos yet but ill take some and put them up once i get to stop overheating! Quote Link to comment Share on other sites More sharing options...
Bean Posted October 30, 2012 Report Share Posted October 30, 2012 Vid of it in action would be great! From what I can see your hoses look fine, except I would rotate that reservoir feed you have in the bottom rad hose so that it's at the top of the hose. Air needs to go up and out of the system at any high spots, so with it pointing down it can trap air in the top of that hose pretty easy. If you can make it the high point with the reservoir feed at the very top that should be perfect. Keeping the reservoir well above that hose will ensure the system stays air lock free. I also think you should install a t-stat just to make sure as well. Running a diesel out of operating temp isn't ideal at all. If you are overheating then you have bigger problems that need to be sorted out and removing the t-stat only makes sense if it's stuck closed and you need to make an emergency repair to get home. Oil leak - the turbo has an oil feed line on top that goes right to the middle bearing section - I bet that it's leaking there. Make a little gasket for the flange and you should be good. I wouldn't risk RTV as too much and it could plug the turbo in a hurry and take it out. Rabin Quote Link to comment Share on other sites More sharing options...
andrethx Posted October 30, 2012 Report Share Posted October 30, 2012 hey jenyus yours is not the first peugeot-powered off-road vehicle...in the 80s and 90s, certain configurations of the portuguese umm alter 4x4 had the 2.5 intercooled turbo diesel engine. you can find more info here... andré Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 30, 2012 Author Report Share Posted October 30, 2012 That's pretty cool Andre! I've never seen one of those before. They look like fun! Also wanted to note that the motor got up to 250F yesterday but the reservoir never overflowed and I know the caps good. So it seems to not be building adequate pressure. Otherwise the 250F would definitely pop the cap Quote Link to comment Share on other sites More sharing options...
Bean Posted October 31, 2012 Report Share Posted October 31, 2012 Careful with overheating as that's a very quick way to blow the HG, or worse warp the head in addition to the HG. Rabin Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 31, 2012 Author Report Share Posted October 31, 2012 yeah, i know, i just had to make it off the trail. still had to stop every 5min and let it cool down. that was on the final stretch! what do you think about it not boiling in the reservoir? when i took the reservoir cap off, boiling water rushed in, but vefore that the reservoir was cool and both hoses were cool. i guess i should probably pull the water pump and check it out, just kind of a hassle. does it sound like a water pump issue? Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 31, 2012 Author Report Share Posted October 31, 2012 here are some more pics. this is with the pug resrvoir i put back on to see if it made any difference. it didnt. vw rervoir is in the same spot. things are still super ghetto rigged, haven't had time to go through and clean everything up like wiring and all that. figure ill do that once it runs right and doesnt overheat. parts are hard to find here in the US and help is even harder to find. thanks for all your help guys! you're the best! Untitled by jofkeiter, on Flickr Untitled by jofkeiter, on Flickr Untitled by jofkeiter, on Flickr current less than ideal exhaust set up but it works. just dont like having the filter so close to the exhaust lol. filter will be routed further forward and exhaust will go out through the hood with a 2in stack and rain flap Untitled by jofkeiter, on Flickr some more pics of the oil leak area. not sure if its leaking from there or just throwing oil all over when its running Untitled by jofkeiter, on Flickr Quote Link to comment Share on other sites More sharing options...
Bean Posted October 31, 2012 Report Share Posted October 31, 2012 Definitely not the oil feed line unless it's leaking in the line and spraying the manifold? Nothing else up there other than the valve cover gasket that I can think of. Did you try moving that coupler in the lower rad hose around so that the nipple connection to the large tube is pointing straight up? If there's a big air lock in that lower rad hose the pump might not be able to get any circulation going. As for parts - have you called any of the vendors? Rob Courter at Javel, Madhu at Parts Network, Brian Holm at Peugeot Holm - all have help me out tremendously and I've never not been able to find anything I've needed. Rabin Quote Link to comment Share on other sites More sharing options...
jenyus Posted October 31, 2012 Author Report Share Posted October 31, 2012 It doesn't appear to be the valve cover gasket as there isn't any oil between the valve cover and intake/exhaust manifolds. I pulled the hoses apart down there but I need some new hoses before I get it all back together. I'm really hoping this isn't a nightmare getting it to run right. I had an Audi that was plagued with overheating issues and I eventually had to just get rid of it after wasting a ton of time and money. I'm just afraid that I'm cursed with cooling issues since I wasn't able to figure that one out! Sorry I should have been more clear, I havent had any trouble ordering parts online just can't find anything local usually. It's just annoying to have to always order parts and pay for shipping. Quote Link to comment Share on other sites More sharing options...
jenyus Posted November 2, 2012 Author Report Share Posted November 2, 2012 just to confirm: that special piece i made on the lower rad hose should be going to the reservoir, right? the middle port on the radiator just goes to the heater, core, right? Quote Link to comment Share on other sites More sharing options...
Bean Posted November 2, 2012 Report Share Posted November 2, 2012 just to confirm: that special piece i made on the lower rad hose should be going to the reservoir, right? the middle port on the radiator just goes to the heater, core, right? Not sure what you mean by the middle port on the radiator since you're not using a Peugeot rad. Heater core should be fed from the engine side, and it can drain into the rad direct. The lower rad hose piece you made should be fine to the reservoir as the bottom drain to the reservoir just needs to be into the system at some point. There was a good discussion on coolant hose routing on my car, and while it's an XD3T 2.5L it should be similar enough to give you an idea at least of the Peugeot set up. http://www.505turbo.com/forum/index.php?/topic/2222-1986-505-td-wagon-w-4sp-auto/ Rabin Quote Link to comment Share on other sites More sharing options...
jenyus Posted November 3, 2012 Author Report Share Posted November 3, 2012 thanks! thats definitely helpful! wish i would have seen the xd3 top radiator hose earlier, it would have made finding another radiator much easier. and sorry i meant the middle port on the water pump, thats the one that that goes back to the heater core, i believe. our water pumps are a little different. mine looks like this Quote Link to comment Share on other sites More sharing options...
jenyus Posted November 15, 2012 Author Report Share Posted November 15, 2012 FIXED!! It ended up being that little port on the top that goes back to the reservoir. I stuck a pice of bailing wire through it and cleaned it out and it's fine now. It's not overheating anymore but I do need to rework that top hose. It popped off yesterday while I was leaning over it and burned me pretty good on my arm and side . Thanks everyone! Quote Link to comment Share on other sites More sharing options...
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