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Discussion Starter · #1 ·
Hello all, I’ve searched threads, poked around a good bit, looked through the rave manual, and replaced parts referring to relevant posts, and my problem is slightly better, but not fixed. My 98 D1 is slowly cooking itself. Never overheated, but runs hotter than “normal”. Using an UltraGauge, at idle and slow speeds under 10mph it runs fine - 188 to 195 degrees or so. On the highway, or consistent speeds above say 40mph, the temp bumps up to 210-212. Highway, at 65-70mph I’ll see 215 degrees, uphill pushing hard - 219 degrees (ac on or off doesn’t matter).

History – a month ago I drove it to VT from NJ on a cool night - first time using the UltraGauge. It hit 225 going up hill at 65mph, ac off, I backed off and it came down a bit to 219. That was the hottest I’ve ever seen - of course the dash temp needle stays a little below 9 o'clock at all times. After reading posts and logically trying to decipher the issue, I replaced the thermostat (did nothing), then the radiator – a RockAuto Nissen (ran a little cooler), because my stock radiator did have some scaling when I looked into the cap, then I finally replaced the water pump. The old water pump had a little notching when turned by hand when I removed it, no leaks, fins were okay, so this probably wasn’t it. After the water pump replacement and no change in highway temp driving, I thought maybe I got a bad thermostat, so I purchased a new thermostat and tried again. No change – still at 212-215 on the highway, perfect at idle. I thought maybe it was a bad temp sensor, but it is hot after a highway stint - the hood latch and prop rod are very uncomfortable to touch without gloves or a rag. The electric fan does come on with the a/c and stays on when hot - key out of the ignition. The fan clutch is still stiff when cold. The system does not lose coolant, coolant is clean, no bubbles in the coolant when on, the engine oil is still clean after 500 miles, I burped the system twice between every parts change (and no loss of coolant), the flow of coolant at the upper radiator plug is consistent when when burping the system, will even overflow quickly when giving a little gas when burping. I feel the disco is slowly cooking and I’m slowly getting more grey hairs trying to figure it out.

This isn’t a daily, so I’m not driving it consistently, especially since we’re in a heat wave right now in the 90’s. The disco has 76,000 miles, I am not the original owner.

Could I have received a bad new Nissen radiator? I ordered a temperature gun and will run it across the new, installed radiator when I get it tomorrow. Should there be a difference from top to bottom, left to right? I have the old radiator still and was planning on having it flushed/rodded and kept as a spare – should I have that done and try the old radiator again? Are blockages elsewhere in the cooling system common? Thanks for any advice!
 

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Discussion Starter · #2 ·
So, I decided to try an oem thermostat. Ordered it today from Atlantic British. Should be here by the end of the week. I'll post my results. Also I want to note that the serpentine belt is installed correctly, the expansion tank cap is not leaking coolant while maintaining consistent operating temperature, and 30 min after shut down - releases remaining pressurized air when slowly unthreaded.

The most definitive data from the fancy new fluke temp gun was after a 15 min heat-up drive, the thermostat housing was 204 degrees and the lower radiator hose halfway to the water pump was 189 degrees on a 93 degree day. This spread remained constant at idle while the system cooled down parked in the driveway, hood propped open. Can anyone comment on the average temperature differences in regards to their personal experiences between the inlet and outlet hoses of the radiator?
 

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I'm no expert but you mentioned scaling in the radiator. Maybe you have a blockage somewhere due to scale or other crap in the block? Some loose piece that blocks a coolant passage when the pressure increases but settles down under lower pressures at idle.

I had a rusty flake of metal do this in an old Ford Courier years ago. It turned out to be lodged in the thermostat and when the pressure was low it bobbled around but when rpm went up it lodged itself enough to block the flow.

If the new thermostat doesn't solve the problem you may want to flush the block manually with the radiator hoses disconnected and the block plugs removed.


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Discussion Starter · #4 ·
I'm no expert but you mentioned scaling in the radiator. Maybe you have a blockage somewhere due to scale or other crap in the block? Some loose piece that blocks a coolant passage when the pressure increases but settles down under lower pressures at idle.

I had a rusty flake of metal do this in an old Ford Courier years ago. It turned out to be lodged in the thermostat and when the pressure was low it bobbled around but when rpm went up it lodged itself enough to block the flow.

If the new thermostat doesn't solve the problem you may want to flush the block manually with the radiator hoses disconnected and the block plugs removed.


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Thanks LAclassic, yes there was a good amount of grey matter in the old radiator. I'll definitely try that next with what I read somewhere else to use a mild solvent, I think cascade? I'll do some more research before introducing soap in the block. I should really purchase some stock in automotive coolant manufacturing though.

I put in the Atlantic British thermostat this evening, burped the system, and drove it at 50 mph. It started at 192 degrees, creeped up to 201, so I headed home where it hit 204 at cruising speed, then I let it idle to cool off in the driveway.

I think the very next course of action is to do what I should have done a long time ago - block test and see if there's any carbon monoxide in the coolant, maybe burn a little oil from the dipstick. Just because I don't see it doesn't mean it's not there, and of course it never overheated, so this could be an early sign of head gasket failure. I'm starting to think I started "just another head gasket to replace thread", in which I hope I'm not posting useless information. I'll report back again.
 

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you said radiator is new, while out did you check the condensor for clogged fins restricting air flow?

at idle and low speeds your clutch fan draws air, at higher speeds it freewheels cause air should be rushing through from vehicle speed

if that checks my guess is air in system or head gaskets cause looks like you did everything else

i run a 180/185 stant with the bleed hole at 12 o clock

you need the right front wheel on a curb or ramp to bleed air got to get that fill plug on the rad up highest point
 

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Discussion Starter · #6 ·
Thanks TOM R. I blew out and cleaned the area between the condenser and radiator when replacing the radiator with compressed air. I tried an alternate 180 degree thermostat first, but the motorad one I tried appeared to have a small orifice compared to the stock, so I took it out, and now a new stock is in there. I'm pretty sure all the air is out, I bled it in the driveway which has a slight incline, with the front right tire parked on a 6x6... I haven't touched the disco since last week. I'll be sure to post my findings once I get the coolant tested, and maybe burn some engine oil on a hot metal surface.
 

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I would check compression ,and look for exhaust gasses in radiator. Consider the main fan and fan clutch as well... lots of info on testing fan clutch here. Sounds like your going down the "need new heads" row though. .
 

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Discussion Starter · #8 ·
Thanks Wadogurl. Well, the blue fluid NAPA block test kit proved nothing. It stayed blue, no change in fluid color. So compression test is next. Fans work, I can hear it. There's not much left to do. I'll start pricing up head gasket kits, can't possibly be more involved than my dohc subaru... Do people still purchase through PT, or another recommended resource?
 

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Discussion Starter · #10 ·
Hi Tom R. No codes, no issues with idling, haven't checked the fuel pressure at idle. Good idea to check too if it's running lean, I see you had an ecu fuel pressure issue. I just read through your whole thread, great to see your d1's transformation. Now that I know you went through a good amount, I may be bothering you with questions...
 
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