Heater Matrix Update (or Saga)

[ChasR]

Please bear with me as I add pictures. It seems Photobucket is acting a little funny.

This may not interest many, but I guess it's another 'work' thread to add to the list on this form. After 5 months of daily use, the S2 came off the road around a month ago, when the heater matrix going was the final straw. I was told after the engine swap that my cooling system was not in its first flush of youth either, and that come March time, it may not be up to the job of keeping the car cool.

As a result I decided to change the matrix and cooling system in one large hit (I guess it's all cooling related). The rad I aquired from ECP (it seems the S2 rad has been superseded by the 250BHP 951 item (the tanks are slightly larger), with the hoses coming from Berlyn Services with other small trinkets coming via my local OPC.

Changing the radiator was actually an easier task than I thought it would be. I'm not sure if I would have agree with my Indy's diagnosis completely (I agree that some of the cooling hoses were swolen and generally old), but I guess it will all help to keep the car cool. I will let the pictures do the talking:

New vs. Old (top of the old rad has been cleaned with pre-Paint for clarity:

As a result, the cooling is all done and dusted which left the job I tried to procrastinate from... the matrix. I couldn't really drive it anywhere as it started to leak quite badly (read steam in the car coming from the floor and a slow puddle forming...

Another matrix was aquired from Porsch Apart, and taking the car apart was not as tricky as I imagined. I thank James G of this forum and a chap by the name of Kevin for their advice on how to go about it. However, as always things do not always go to plan.

Some before and after pics. I simply got into the rhythm of things and got on with it (hence sorry for the lack of pics). Nasties in the loom didn't really include any, bar some crimped connections for an ISO block to allow a modern HU to work, which I've since resoldered around a day ago with more sensible runs of speaker wire:

The dash is back in (bar the bits of trim to go on it (read on and you'll see why)) although whether it will stay in is another matter. I managed to get one of the two pipes of the matrix secured again using the C Clips. The second pipe with the seal in place (I aquired new items from my OPC) seems to be intent on not joining. Without the seal it is fine, and without the dash in place doesn't seem to make life much easier.

So in one sense it's success, but it also feels like I am back to square one with another leak if coolant is added (albeit not a failed matrix). Now to figure out on how to close that join enough so as for the clip not to slip off time after time again. I certainly hope that the car will again soon.

Finally, a pic of the join bringing the whole car to a halt:

Poor car in it's resting place...:

And no, those oil marks are not from the Porsche but a previously leaky Volvo 740 that leaked oil like the Exxon Valdez. I guess at least it ran.

 

[Diver944]

Well done on getting the bulk of the work done youself (its a lengthy project changing all of that and will bring its benefits in the long run). I feel your frustration trying to get that hose to stay in place [], have you tried any sort of rubber cement as well as hose clamps?

 

[sulzeruk]

It should fit Chas, persevere with it. Check to make sure that the edges of it are perfectly round as they are very thin and easy to flatten. If the pipe fits in without the seal OK, there is obviously something slighlty tighter on the outside diameter. Check it very carefully and straighten accordingly,
Alasdair

 

[ChasR]

Rubber Cement, never thought of that. I have considered going sealess, or using an old seal and using Boss White or LFX pipe Sealer but am seeing what else I can do.

When you say hose clamps what in particular did you have in mind?

Alasdair, I'll check the pipes again. I know the matrix from Porschapart came with another set of pipes in the deal (so not too badly priced really assuming the matrix is fine). But the top pipe looks like a royal pain to change with the engine in the way... Ah well fingers crossed that the car will see tarmac again.

 

[James_G]

Hi Chas

Good to hear that you got the matrix in place - glad I was able to be of some assistance on the phone during the process.

As for your pipe, I do remember it being a tight fit, even with the seals on mine not being new. I think I used some silicon grease to help it on its way. So frustrating these things though - it's the last step that's stopping the job being complete. I feel your pain []