Coolant flow diagram / Picture needed

[Pudsey]

Hi im new here, and am after some help.


I recently changed the engine in my galaxy (1.9Tdi 115hp AUY engine) for a less travelled one, however during the transplant process my coolant pipes where mixed up and all disconnected (By my less than helpful brother) so i am after a diagram or pictures if you can of the coolant pipe route around the engine bay.


Can anyone please help


Thanks in advance

Pudsey

[bestfc01]

Hi Pudsey and 

Have you taken a look at the parts list? (link below)

http://eucatparts.com/?action=cat_ford_unit&s_id_grp=4419&s_id_model=99

Your need to look at the one which is more relevant to your current layout, however this may give you some indication.

If not, i'm sure one of the guys will be along shortly

[johnnyroper]

Bottom rad to thermostat housing
Top rad to housing right hand side of head
Left hand egr cooler to electric cooling pump
Right hand egr cooler to housing on side of head
The small bore ones from expansion bottle connect too plastic part of top hose than to side of engine.

With the shapes and sizes of them any others should be able to be matched up.

[Pudsey]

I think i have them correct, but im getting a lot of pressure in the system after a while of running. Hot air in cabin and NOT over heating at all. Had a new thermostat.

[johnnyroper]

Might just be air in system still,have a check of the restrictor that is located in small bore pipe leading to expansion bottle. It is about half way up the pipe you will need some wd40 and a long screwdriver to push it out,should have a small hole in it. Run a 2mm drill bit through to make sure it's clear.
If after checking that and allowing system to vent overnight with cap off it is still pressurising could ha e potential head gasket issue?

[Pudsey]

Update for you guys, Upon looking at the restrictor in the return hose i found it to be a pin hole. That has now been sorted (2mm Drill bit  ) I'll be leaving cap off to vent tonight.

Now when i drive it it still pressurises and I've noticed that the bottom hose (To thermostat) is cold and the top hose is hot. Any other ideas?

Really starting to annoy me now. Silly hot air in cabin, No overheating, No cross contamination of oil / water.

For all your input so far

Pudsey

[johnnyroper]

Leave it to vent and try again now restrictor is clear.

The bottom hose is always cold unless you been on a good motorway run or under serious load like towing,these Moines are very thermally efficient so stat don't open unless it's worked hard