what rads fit in an mk1?

[8v-of-fury]

I have several. Original 81 mk1 rad, two 91 rads, and a 98 rad.

The mk3 rad is too tall, so without notching it won't work.

The 81 rad is kinda beat up and has paint all over the fins which is why i am looking at replacing it.

The 91 rads do not have the over flow nipple, but I think that is ok as the TDI motor's small over flow tube comes from a small nipple on the front coolant flange.. Will the 91 rad physically fit in the 81 chassis? bot my 91 rads are from non a/c cars if that makes a difference.

[theman53]

I am pretty sure the 675mm rad from A/C cars work. Someone might have a post about putting one into a caddy? The non a/c cars I thought had much smaller rads and if you are building a TDI with power I would try to get the a/c rad if possible.

[8v-of-fury]

Lucas I think your thinking of GEE-BEE, he put a 675(or w.e) rad fan in his caddy.. Dunno if he did the rad as well or not?

Yeah the tdi will be making more power, but is 15% more efficient than our idi's so it shouldn't need as much cooling capacity.. One would think.. The smaller non ac rad should be sufficient.

[theman53]

Yep Gee Bee and he had the big rad for sure, so if it will fit in a caddy = MK1 it should fit in yours.

I would rather have the cooling if possible, but if you have rads then run it and see I guess.

[R.O.R-2.0]

you gotta use a mk1 radiator in a mk1.. i really doubt the 91 radiator is gonna fit, they are soo much bigger

[8v-of-fury]

I went home for lunch today, and I roughly test fit the mk2 rad.. It will fit height wise and clear the hood, I think its only a tad longer.. Which isn't a problem either.. Got nothing up there to be in the way.

I wonder, does any one have dimensions of the ac rad in comparison to the non ac mk2 rad?

[GEE-BEE]

525 MM , 568 MM A/C model ,675mm a/c or non a/c will fit

Will fit, I have installed all model's

The 675 mm , 16v non a/c is a straight top outlet,and has a nipple for the overflow.
 the a/c is a angle top outlet and there is no nipple for overflow, it is built into the top raditaor hose assy.

The 675mm radiator new is half the price of the 568 mm( MK1 a/c )model

You will need the different rad brackets to mount ( 12.00) for a set

I have a extra mkII shroud ( fresh powder coat and new rubber's )and a new 250 watt two speed fan if need be..

I make both hoses for this application, along with the a/c model also

Iam running a passat dual fan assy 1991 model 4 cylinder
It turns on at 205 and runs the fan's for 7 seconds, very quiet, almost the full width of the radiator which adds better cooling

GB
pic's or part #'s [email protected]

p.S. I just finshed all ten hose assy's for the Scirocco 16 v, and Iam starting the rabbit GTi Mk1

[GEE-BEE]

MKII A/C and Non A/C are the same length except for the top outlet
Both model's have angled outlet

I have two new a/c 675 mm, Beher radiator 675 mm if you need one

you will have to use a special hose with a built in overflow hose

GB

[Rabbit79]

A 675 can be done. I'm putting one in right now (yes I got it from GB). It's tight but it will fit. My car is a 79, and I know the MK 1 changed a little bit in 80. It's been a long time since I looked in a post 80 engine bay but I don't think they changed much in there so it should all be the same as what I have. The tightest spots are going to be around the alternator and the vaccuum pump (I have the diaphram style vac pump). Here's a pic. It's in the mock up stage now that's why it's being held in place by a roll of paper towels  hehe. I have more pics if you want to see details. I put it in full size so you can see as much detail as possible.

[GEE-BEE]

Dont forget to install the 5/8 pseal to fill the gap between the rad and the core support

I rotated my battery 90 degree's with a cnc optima mount for more room

it will be there until the dual battery ER40 ( odessey's) mount is complete for under the bed

Drill two holes for this type of rad , since it uses a pin mount and not the stud type with rubber bumpers on the pin..

GB

[Rabbit79]

I got the P-seal glued on today, and everything is drilled and it's ready to go in. Actually the battery didn't present any problems, it was the alternator that caused the main trouble. I had to switch those brackets around for the fan shroud to mount it all the way to the left of the radiator, because it was hitting the back of the alternator, and I had to put the radiator far enough to the passenger side to get the lower hose connection under the alternator. I tried to put the radiator as far to the driver's side as it would go but the alternator interfered with that. The fan shroud is also very close to the vac pump but it does clear it by a little. Of course my vac pump being the diaphram style is bigger than the other kind (at least from the pictures I've seen, I've never actually seen the vane style in person). I also had to change around the upper mounts a little bit because they sit right where the hood support rod locks into place. Here's a couple pics.


In the first pic you can see it's a pretty tight fit for the lower hose but it does work. In the second pic you can see the MK 2 style mount and where it sits on top of the core support, which is right where the hood support rod lays...... all I did was cut off that part that sticks down and drill a hole through it and the rear of the core support and thow in a bushing to take up the empty space and put a nut and bolt in there.

[GEE-BEE]

I installed the hose on the radiator first, tighten with 8 mm

Nice clamp's you must stay for hoses

These mounts are much sturdier the the MK1 C clip

I removed the hood rod and installed some lift strut's

Mix the catalyst up well with the silicone cement, I usally tape the seal down with paintes tape when Iam working with cold weather temp's, The cement is made by G.E. and is around 1275.00 for a 40 lb pail
GB

[junn1227]

My first attempt was not as successful as I had thought.     My question is primarily regarding the lower hose.  I used the mk2 lower hose and here is the issue:

1.) The hose is touching the lower alternator bracket.

2.) The hose is very close to the alternator belt.

3.) The hose may be slightly short.  I had to literally stretch the rubber to get it on the waterpump.

The radiator is off a 92 gti 8v with ac.  The radiator was installed identical to how it is pictured in the earlier post.  What kind of hose did you guys use?  Thanks for the help!

[GEE-BEE]

The 16v scirocco 533 121 051 A, has a angle turning more downward

the other one that will work is the 191 121 051 p

Please post pictures

I make both of these in silicone,

remember the Scirocco 675 mm non a/c radiator is cheaper than the 568 a/c radiator found onthe stock mk1 rabbit model's

GB

[Rabbit79]

My first attempt was not as successful as I had thought.     My question is primarily regarding the lower hose.  I used the mk2 lower hose and here is the issue:

1.) The hose is touching the lower alternator bracket.

2.) The hose is very close to the alternator belt.

3.) The hose may be slightly short.  I had to literally stretch the rubber to get it on the waterpump.

The radiator is off a 92 gti 8v with ac.  The radiator was installed identical to how it is pictured in the earlier post.  What kind of hose did you guys use?  Thanks for the help!

Here's how it worked out for me, as I had basically the same problem: I ended up using hose 533 121 051 A. The other one that GB mentions wasn't long enough to work on my car(might work on yours, don't know exactly what you have). I had to cut a little bit off the water pump end to get it to reach the radiator connection. It's a very tight fit.... You can see in the pics the clearance between the alternator fan and hose is only about a 1/2 inch. You can also see the alternator body to radiator clearance is pretty close as well. The alternator does run through it's full travel when it's loose without ever hitting the hose, so even if it were to come loose I don't think it would chew it up. The fan belt pulley has a little more clearance since it sits up a little higher. I wouldn't have minded putting the radiator a little more over to the passenger side, but when I tried that the fan shroud hit the back of the alternator, so right where I've got it is about my only option. I was a little worried that the engine might rock back and forth under load and cause some problems, but it's been in and running for about 100 miles so far and no problems yet. I also cut out the slats in my grill to get full flow through the radiator, as part of it was blocked off due to the narrower stock radiator. Jig saw with a metal cutting blade whipped it right out. Sorry the pictures from below suck... I had to hold the camera right on the floor to take those so I couldn't tell exactly where it was aimed. Also for reference the radiator I just put in was 675mm (26 5/8") core width, and 768mm (30 1/4") overall width.