Hi,

Advice needed (Zetec, Polo rad and no Heater), Can anyone help with my plumbing?

So far I've managed the two rad connections ie top to Thermostat and bottom to Engine. Just need to know the following:-

1. Where does the header tank connect onto?

2. Where does the 3 remaining connections on the thermostat housing connect onto???

3. Where does the small connection on the top of the rad goes to?

thanks

Ian

The smaller connection on the exhaust side below the main thermo output needs to go to a T in the rad to engine bottom hose. It acts as a bypass circuit until the thermostat opens and stops hot spots in the engine during warm up.

The connector pointing to the inlet side of the engine needs to connect also to the bottom hose.
Tiger do a ali pipe with two connections to allow both of these smaller pipes to be fitted into the larger bottom hose, cost about £20 but a good neat solution. The header tank need to connect also to the bottom hose, but does not require a direct connect as in the other two so a T piece in the second pipe is fine.

The small connector on the thermo housing goes to the small connector on the header tank and serves as a bleed.

The small connector on the rad can be blocked off. Use a set screw and it can also be used to bleed the rad during filling.

I also found a need to fit a 15PSI header tank cap as the system presure is high nd will blow past a 8psi cap.