Hi all

Just trying to get my head around this - running a Zetec turbo, added plumbing for the turbo - can anyone confirm if this routing is ok? Specifically the routing for the turbo cooling.

PS credit to forum owner of original image (which I have butchered!)

Thanks

Darren

That looks wrong to me.

Coming out of the thermostat the coolant is leaving the engine so hot,that pipe that runs to the lower rad hose is wrong as that would be putting hot coolant into the coolant that's been cooled by the radiator.

Also the small 'bleed' pipe coming off the top of the rad should go straight back to the top of header tank,this bleeds off any air in the rad.

couldnt fit on pit but the turbo has its own mini radiator so water comes from engine (hot) then goes through turbo rad (cools) then through turbo, then back to top of radiator.

The 'red' pipe that goes from thermostat to bottom hose (just before pump) is used when the thermostat is closed, eg so water is still circulating even when thermostat is closed.

Login taken from here:




[Edited on 10/9/18 by Daz1234]

original diagram was from

http://www.locostbuilders.co.uk/viewthread.php?tid=178112

Ford used a take of direct from the head, sandwiched between the head and the thermostat housing. They then returned it to the thermostat bypass hose.

The bypass hose and the header tank should be T'ed in near the water pump. What is referred to on the donor as the spider hose.

If you do it nearer the thermostat some people have found a pumping up affect on the header tank.

The bleed on the top of the rad should be T'ed with the bleed on the thermostat housing and the one on top of the header tank.

[Edited on 11/9/18 by big_wasa]

quote:

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Originally posted by big_wasa
Ford used a take of direct from the head, sandwiched between the head and the thermostat housing. They then returned it to the thermostat bypass hose.

The bypass hose and the header tank should be T'ed in near the water pump. What is referred to on the donor as the spider hose.

If you do it nearer the thermostat some people have found a pumping up affect on the header tank.

The bleed on the top of the rad should be T'ed with the bleed on the thermostat housing and the one on top of the header tank.

[Edited on 11/9/18 by big_wasa]

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Hmm. Firstly to be clear, is the turbo rad cooling the turbo, and is not a water/air cooler for the compressed air?

Any pumping system that had parallel runs is a bit pot luck regarding flow, the majority of the water will take the path of least resistance.

My guess is the turbo would be happier running at higher temp than the engine so why not have one circuit.

Engine - turbo - radiator.

[Edited on 11/9/18 by 02GF74]

quote:

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Originally posted by 02GF74
Hmm. Firstly to be clear, is the turbo rad cooling the turbo, and is not a water/air cooler for the compressed air?

Any pumping system that had parallel runs is a bit pot luck regarding flow, the majority of the water will take the path of least resistance.

My guess is the turbo would be happier running at higher temp than the engine so why not have one circuit.

Engine - turbo - radiator.

[Edited on 11/9/18 by 02GF74]

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your diagram is still wrong mate.

You have the coolant feed from the stat. This doesn’t flow constantly. Only when the stat is open. The Turbo would see no flow when cold.

You have the turbo returning to the radiator bleed. this is an out let to expel any air that's got trapped like the one on the thermostat housing. They both go to the top of the header tank.

The turbo return wants to go to the bottom hose near the water pump like the thermostat bypass and header tank although you could put into the bypass hose as per pic. but don't put the header tank into it as well.

Turbo supply wants to be direct from the head either Fords sandwich plate or tap the head behind the coil bracket.

ref for the picture ive butchered is Daf



[Edited on 11/9/18 by big_wasa]

This is what ford used on the Focus Rs.



I think it’s an m14 banjo with a 12mm I’d pipe.

In action....

What hp are you planning on running ? I’ve seen the airtec pre turbo rads but I fail to to see any gains in a modest set up and I would say the charge temperature is more important

Thanks guys. few questions:

1. "radiator bleed. this is an out let to expel any air that's got trapped" - ok but is it one way - eg can water flow in or only out? Just wondering whats causing the issues im having with water coming back up into the header tank).

2. Turbo return: surely you would want to put the return from the turbo (by this time bloody hot water) back through your main rad to cool it no?
Otherwise you are putting that boiling coolant straight back into the engine?

3. You have lost me re feeding the turbo directly from the head - Why is that? Where does that plate go?

PS im running a T3 at 1bar. Probably dont need it but just wanted to add water cooling to the turbo as a added bit of protection (why not I thought ...) - I have the airtec rad which ive installed on the car.

Help very much appreciated

That alloy plate is sandwiched between the head and the thermostat housing.
I.e. the coolant is taken direct from the head to the turbo.

The bleed is what it says.

Re backing up your header tank have you connected it to the bypass hose or the spider hose ie the pipe from the water pump.
I know it looks the same thing but plenty of people have found it doesn't do the same thing. Of course for every one that says it doesn't work thrre will be some one that says it does.

Re the turbo pre cooler. I've not come across any one that says it's needed at the 250hp your shooting for. I would get it working with out and add it latter if there is a benefit.

I would pay more attention to charge tempreture.

Thanks for your help

Ok I think for now ill bypass the turbo cooling and get the rest of it working correctly as you say..... Ideally I want to use it, if nothing else for the time and money to get it all lol

Do you know where I can get the alloy plate from should I choose to add it in later?

Bleed - before I tried to add this turbo cooling I used to have the bleed on the main radiator capped off, as well as the bleed on the header tank (see pic). Just had a bleed running form thermostat to header tank as per pic below.

Seemed to work ok but should I hook up the bleed on the rad to the bleed pipe on the header too - and if so which pipe should I connect to (see pic below - in green)



Backing up header - the header tank tee's into the bypass hose currently - see pic below - which then tee's into the 'spider host' (eg the one that goes to pump).

So in your pic you have 2 separate hoses running to the 'spider' hose (one from header, one from thermostat) where as on my plumbing I have joined/tee'd the two together just by the thermostat and ran one hose down to the 'spider' hose. Maybe that is the problem there and I should run the two separately?.



Thanks again!

Yes if you do a search lots of people have had problems with the header backing up when T'ed intro the bypass. (Not every body)

Not all radiators have a bleed but if you have one I would use it as it just works.

Your alloy header looks to have an over flow ? I.e. above the cap. It shouldn't be over flowing to need piping it.

The alloy adapter plate is no longer available from ford. There are billet ones on eBay but an An6 fitting into the head is a cheap solution.

Don't bypass the turbo coolant but I would hold of the pre rad until its sorted.

What's it in ?

I would also have the turbo return to a separate spur in the bottom hose. Ik know it adds to the plumbing.

Thanks for the reply. MK Indy.

Never used to have water cooling on the turbo... was just something I wanted to add.

Just so i'm clear and before I go buy a load more hosing and connectors

1. I want the rad bleed and thermostat bleed to t-together and go to the top right fitting on the header tank?
2. The other fitting on the header tank.. 'overflow' (just under the cap) should I just run a hose from that to the floor?
3. So I need to run 2 separate hoses to the 'spider hose' - 1 from header, 1 from thermostat (the bypass)?
4. where should I ideally plumb the in/out for the turbo?

Thanks again.

PS "billet ones on eBay" - what would I be searching for?

I am not saying this way is the only way it will work but it's how Ford did it in the Focus Rs and it works.

eBay Item

[Edited on 12/9/18 by big_wasa]

quote:

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Originally posted by Daz1234
Thanks for the reply. MK Indy.

1. I want the rad bleed and thermostat bleed to t-together and go to the top right fitting on the header tank?

Yes.


2. The other fitting on the header tank.. 'overflow' (just under the cap) should I just run a hose from that to the floor?

Could do. It stops coolant over flowing into the car and over your feet if it does over flow.

3. So I need to run 2 separate hoses to the 'spider hose' - 1 from header, 1 from thermostat (the bypass)?
Yes

4. where should I ideally plumb the in/out for the turbo?

Ideally a third separate hose to the spider hose or T into the bypass hose.

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quote:

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Originally posted by big_wasa
I am not saying this way is the only way it will work but it's how Ford did it in the Focus Rs and it works.

eBay Item

[Edited on 12/9/18 by big_wasa]

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1. I want the rad bleed and thermostat bleed to t-together and go to the top right fitting on the header tank? 

Yes. 


2. The other fitting on the header tank.. 'overflow' (just under the cap) should I just run a hose from that to the floor? 

Could do. It stops coolant over flowing into the car and over your feet if it does over flow. 

3. So I need to run 2 separate hoses to the 'spider hose' - 1 from header, 1 from thermostat (the bypass)? 
Yes 

4. where should I ideally plumb the in/out for the turbo? 

Ideally a third separate hose to the spider hose or T into the bypass hose.

quote:

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Originally posted by big_wasa
1. I want the rad bleed and thermostat bleed to t-together and go to the top right fitting on the header tank? 

Yes. 


2. The other fitting on the header tank.. 'overflow' (just under the cap) should I just run a hose from that to the floor? 

Could do. It stops coolant over flowing into the car and over your feet if it does over flow. 

3. So I need to run 2 separate hoses to the 'spider hose' - 1 from header, 1 from thermostat (the bypass)? 
Yes 

4. where should I ideally plumb the in/out for the turbo? 

Ideally a third separate hose to the spider hose or T into the bypass hose.

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I figured Ford new what they where doing when they turboed the Zetec in the Rs.

So what inlet manifold are you running ?

Haha true

Custom made

So, got a picture ?

quote:

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Originally posted by big_wasa
So, got a picture ?

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