Author Topic: C4 1987 Throttle Body Coolant Bypass  (Read 653 times)

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Offline Vettech

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Re: C4 1987 Throttle Body Coolant Bypass
« Reply #12 on: August 14, 2020, 02:01:23 PM »
Still waiting on TB gaskets. So I'll clean up the front on engine ready for bits to bolt on, check out old Water Pump, umm still one of those Stud/bolts in it, even though there are no threads inside the actual pump housing, its as though its threaded down tight.
Eventually, penotrene, largish hammer it came out, a ring of corrosion was all it took to hang on like grim death.

Now they look different, there is no heater spigot/tail in the new pump, the old one is also well and truely corroded in, plus I have no tool that size or depth to get it out - time to source a new one. I do have an enormous shifter, but where, bugger it, just get a new one.

Now - after going to PEP's, getting this bit may not be easy. They had a short tail, but the hex was on the thread's so its impossible to get it tightened down, now what did Sirfixalot do on his...... ummmm.
Vettech.

Offline Vettech

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  • Car: C3 78 + C4 87 + C4 90
Re: C4 1987 Throttle Body Coolant Bypass
« Reply #13 on: August 19, 2020, 02:15:13 PM »
The tail out of the front of the manifold which carries water out of manifold thru a short horse shoe bend hose up into the TB housing, thru housing and out the RH side, well that tail is RS totally, after nearly two weeks of  getting the correct tools, giving it applications of Heat and Ice water, penotrene, 3ft bar, it finally gave up and came out, but only after I used a Lump Hammer.

If any one out there wants a new "U bend hose", also you can have the original funny looking OEM hose clamps. If you want original stuff on your car then you are welcome to them. Let me know.

Now to get a new tail fitting, and run a BSP tap thru the hole. It really was amazing how tight this fitting was in the manifold, I suppose having a type of steel screwed into aluminium, submerged in water for 30 years will give cause for concern, its little wonder why mechanics refuse to work on cars of this age, to us its a simple job and we get miffed when charged extra for broken, decrepid stuff we thought was ok.
Vettech.

Offline Vettech

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  • Car: C3 78 + C4 87 + C4 90
Re: C4 1987 Throttle Body Coolant Bypass
« Reply #14 on: October 22, 2020, 08:25:36 PM »
This TB BYPASS has wanded right thru the car. So far we have done the following:
1. Replaced the water pump. (Leaky & noisy)
2. Replaced heater matrix. This included repairing fire wall holes and heater A/C housing, pulling LH dash out.
3. Modified the TB by removing the inlet/outlet tails ( no more water thru the TB). Fit new gaskets, screws etc
4. Replaced the front manifold water oulet with a 90* fitting with a smaller 8mm tail sweated in, to allow    pickup of the steam vent.
5. Removed, cleaned & painted all the carriers/frames on front of engine.
6. New hose from manifold rear steam vent to front pickup.
7. Re-installed the metal "KC4" line from KC4 up to water pump.
8. Repaired KC4 water tails, re-installed along with new Oil Filter (also cleaned rust out of block at KC4 port)
9. Fit new hoses etc to KC4.
10. Remove A.I.R pump and modify accordingly.
11. Fit new "T" piece, hoses etc where KC4 meets water pump side return and heater return.
12. Obtain "02" V8 Comodore (heater to heater tap) hoses, allowes heater to connect down past frame, turn forward.........
And:
Thats as far as I've gotten, I intend to use GOSS 16mm ID heater hose to connect from "T" piece thru heater then to 90* fitting, also I hope to bend up some 5/8 Annealed Cu pipe to connect the hoses, but at the moment I've not allowed for a heater water tap, but the 5/8 pipe should allow its retro fitting at a later date, but since my 90 has no tap on it, I may in the future depending on how well the 87's A/C works opt for no tap ..... we will see.

And for those who are asking "why is he using 5/8 Cu pipe", well the original "conversion" left a lot tobe desired, all hoses THEY ran had 90* kinks in them, thus blocking flow and promoting corrosion, also one ran right under the engine very close to manifolds, cooking very nicely. The Cu pipe once bent to shape is a smaller cross section than the hoses, can be bent to fit into the tight spaces past the LH manifold and up to and under the Alt and A.I.R pump to pick up the new brass 90* fitting, should look neat and tidy and out of sight.

Now waiting on a 5/8" pipe bender - and yes I know all about sand and springs and things, but I'm getting more decrepid by the week and my hands no longer have the strength of old and besides its another nice tool to hang on the wall, you can never have too many tools.
Vettech.

Offline Vettech

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  • Car: C3 78 + C4 87 + C4 90
Re: C4 1987 Throttle Body Coolant Bypass
« Reply #15 on: October 23, 2020, 03:23:03 PM »
Well it looks like I waited all day for the Bender - maybe Monday.

Also was waiting for a new antenna Diplexer, but allas no TV till most likely Tuesday.

I cant watch Foxtel in the Queens room, that leaves Netflix, Stan or Bob or something, all old rubbish.

I wonder if there something else on the car needs fixing ?!?!...
Vettech.

Offline Vettech

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  • Car: C3 78 + C4 87 + C4 90
Re: C4 1987 Throttle Body Coolant Bypass
« Reply #16 on: October 30, 2020, 05:57:02 PM »
Well today I visited the "Oracle @ the Wilton Black Hole"

Its amazing how you can see a fix but another person see's a different fix.

After discussions, other ideas supporting ways to fix my heater hosing, routes, tubes etc appeared.

Maybe over the weekend I'll be able to put the Oracle's ideas to use.

Also was thinking of a new project for the Oracle, converting a 5/8" bender into a 1/2" bender....... ummmm.
Vettech.

Offline Vettech

  • Supercharged
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  • The rocket sled in Steel Blue.
  • Location: Cecil Hills. N S W.
  • Mood: Electrofied.
  • Car: C3 78 + C4 87 + C4 90
Re: C4 1987 Throttle Body Coolant Bypass
« Reply #17 on: November 16, 2020, 07:30:27 PM »
Well its all back together except for the upper Alternator bracket - had one organised but it fell threw. Searching

Oil is in, no leaks. Water is in, no leaks, yes water for now - as I intend to give it a couple of fill, run, flush cycles. Maybe try the crushed dish washer tablet cycle I saw on a UK web site.

No AC at this point, I have a new Accumulator (VB Comodore SLE) type, why, because it has reversed fittings and since I need to get some new hose/pipe sections made to accomodate the Left/right conversion, the hoses etc will be direct straight forward (easy) making the setup neat & clean, and of course it will he "High Chill -30" type refrigerant.

A tip - used or second hand aluminium A/C hose fittings can be re-used - carefully cut the crimp off, it can be refitted with new ferrel crimp, onto new A/C hoses. Or if you get onto a good AC chappie, he could make new Alli pipes to measure, these are neat and tidy and more compact than the much larger Rubber style hoses. (I saw a late nite show - a guy in Qld making AC lines, bending etc and welding, which I think is more of a Silver type solder, good looking job though).

The cars so ready I decided to kick her over on Friday, but no start, no fuel, cant hear pump running, now I just want to burn it, what next can possibly go wrong.
Vettech.

Offline Vettech

  • Supercharged
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  • Posts: 1303
  • The rocket sled in Steel Blue.
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  • Mood: Electrofied.
  • Car: C3 78 + C4 87 + C4 90
Re: C4 1987 Throttle Body Coolant Bypass
« Reply #18 on: November 18, 2020, 02:18:03 PM »
Well the pump cct is a bit convoluted, and goes from engine (relay) back thru firewall thru an array of connectors before heading off to the pump in the tank. (Keep in mind that on C4's once started the fuel pumps power is supplied by the Oil Press Switch as a fail safe in the event of loss of engine oil pressure.)

Found Relay - it fell apart in my hands, after a clean and test lamp & metre on the bench even as a mess it worked. Thank God for Silastic and black cable ties.
Wires go back into car thru a 15way interconnect ..... which because the dash is still apart was disconnected, re-plugged, hit the key and I got wonderfull smell of fresh petroleum in the morning. Re-fit fuel lines, pressurized the rail and she burst into life. OMG it goes.

Now to get that Alt top bracket, AIR pulley on, belt on, then off to get a pink slip for Rego (MOT), may even put it on H'plates after all it is 30 odd years old. I should be running on double plus ++ H'plates

Vettech.