My 04 D2 rebuild adventure.
Thread Starter
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Mudding
Joined: Feb 2014
Posts: 205
Likes: 16
From: Atlanta, GA
^^ I don't think I've ever seen anyone use this T-stat.
It's the Britpart replacement for the gray 180. Heck it was even listed as being the grey one. It says it opens at 82C, so it's the 180.
We'll have to see how well it does. I liked the price I got it for. All these came in from the UK. Great prices.
It's the Britpart replacement for the gray 180. Heck it was even listed as being the grey one. It says it opens at 82C, so it's the 180.
We'll have to see how well it does. I liked the price I got it for. All these came in from the UK. Great prices.
Thread Starter
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Mudding
Joined: Feb 2014
Posts: 205
Likes: 16
From: Atlanta, GA
Weekend Update:
I tracked down all the plugs and wires. Forgot to mount the O2 sensor plugs when I put on the bell hosing, so just mounted those to the firewall and out of the way.
Merging the TC to the flex plate was a PITA, but that's done. I got the intake on, after a looong soak in degreaser and a power wash. Filthy inside with oil. Pretty much everything is back on except a few old rad hoses, the radiator, tensioner and belt.
The last real issues, pains, will be getting 3/4 tank of gas drained....
and the kicker..
Taking the SAI fittings around town trying to find 4 bolts that will block off the holes in the heads, or 4 caps that will block off the ends of the fittings. Pray that'll be an easy find.
I tracked down all the plugs and wires. Forgot to mount the O2 sensor plugs when I put on the bell hosing, so just mounted those to the firewall and out of the way.
Merging the TC to the flex plate was a PITA, but that's done. I got the intake on, after a looong soak in degreaser and a power wash. Filthy inside with oil. Pretty much everything is back on except a few old rad hoses, the radiator, tensioner and belt.
The last real issues, pains, will be getting 3/4 tank of gas drained....
and the kicker..
Taking the SAI fittings around town trying to find 4 bolts that will block off the holes in the heads, or 4 caps that will block off the ends of the fittings. Pray that'll be an easy find.
Thread Starter
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Mudding
Joined: Feb 2014
Posts: 205
Likes: 16
From: Atlanta, GA
Well...
SHE LIVES!!!
After about 2 attempts, as the fuel lines were bled dry, she fired right up. Then died shorlt after as uh.... well I forgto to bolt the power steering pump to it's bracket. Must have been stuck in there good enough where I didn't know it wasn't.
So, after a run up, we had some issues with running too hot with only water in it. (had a reason for that). We got a few misfire codes on the Ultragauge. 3, then 6, then 5. Cleaned up the plugs, burned off some oil in the cylinders. After a bit of burning off the old gas, and letting the cooling system run, I finally was able to do a 30 minute break in without it hitting 250.
We ran a bottle of Moroso ceramic sealer through it during an hour break in period, then a good hour drive. Temps dropped to 203 running around. Ran nice and smooth. Solid. No more codes. At all actually.
No dash codes. No warning lights. All good. I have to say, I was not expecting that at all. So we dropped the Royal Purple run in oil, and swapped in some 5w-30 dino oil to run it the next 3k miles. Let the seals bed in. Then I'll drop the Rotella T6 5w-40.
Right now the cooling system is bled dry and letting the ceramic set. Tomorrow I'll flush it out and fill with antifreeze. I'll let that run until the new radiator gets here. New radiator, all new lines, and a new 180 t-stat.
I just can't believe she is up and running. Finally. We'll see how it goes from here until I make her the daily driver. For now, I'm getting ready to get married on Friday. I'll finish the truck Thanksgiving weekend.
SHE LIVES!!!
After about 2 attempts, as the fuel lines were bled dry, she fired right up. Then died shorlt after as uh.... well I forgto to bolt the power steering pump to it's bracket. Must have been stuck in there good enough where I didn't know it wasn't.
So, after a run up, we had some issues with running too hot with only water in it. (had a reason for that). We got a few misfire codes on the Ultragauge. 3, then 6, then 5. Cleaned up the plugs, burned off some oil in the cylinders. After a bit of burning off the old gas, and letting the cooling system run, I finally was able to do a 30 minute break in without it hitting 250.
We ran a bottle of Moroso ceramic sealer through it during an hour break in period, then a good hour drive. Temps dropped to 203 running around. Ran nice and smooth. Solid. No more codes. At all actually.
No dash codes. No warning lights. All good. I have to say, I was not expecting that at all. So we dropped the Royal Purple run in oil, and swapped in some 5w-30 dino oil to run it the next 3k miles. Let the seals bed in. Then I'll drop the Rotella T6 5w-40.
Right now the cooling system is bled dry and letting the ceramic set. Tomorrow I'll flush it out and fill with antifreeze. I'll let that run until the new radiator gets here. New radiator, all new lines, and a new 180 t-stat.
I just can't believe she is up and running. Finally. We'll see how it goes from here until I make her the daily driver. For now, I'm getting ready to get married on Friday. I'll finish the truck Thanksgiving weekend.
Pro Wrench
Joined: Nov 2011
Posts: 1,462
Likes: 32
From: Duxbury MA
Your hose routing looks a little unconventional. Where do you have the small hose on the driver's side of the radiator connected to?
Congratulations on getting the truck running by the way.
EDIT: I see how you have it run now. I couldn't see the turn to the reservoir until I zoomed in. Looks good.
Congratulations on getting the truck running by the way.
EDIT: I see how you have it run now. I couldn't see the turn to the reservoir until I zoomed in. Looks good.
Last edited by 04duxlr; Nov 17, 2014 at 03:48 PM.
Thread Starter
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Mudding
Joined: Feb 2014
Posts: 205
Likes: 16
From: Atlanta, GA
Update:
Well I have about 100 miles on the rover so far. I won't be using it as a DD until I have the new cooling system installed. So far the only codes I get on the Ultragauge anymore relate to the SAI that I removed. Fingers crossed nothing else will pop up. The car does seem to idle a little more rumbly than I expected on a newly rebuilt motor, but I'm sure it's still breaking in the engine as well as the ECU is still learning.
The radiator came in last night, Nissens, so that will be going in with a new 180 t-stat and all new cooling hoses this weekend. Then we will see what temps its running at.
After running the car up, it ran at 203-12 on the highway and at stops. BUT, the radiator felt very uneven on heat distribution. The top right was hot, but the rest was mostly cool. I have a feeling the old one was clogged up.
So, Friday I'll drop the new cooling system in, top it off, and then take it out and test. If I have the time, I'll do a drain and fill on the tranny and put in the new filter and gasket that came in.
Then on Sunday use it to move from my apt to the new house.
Well I have about 100 miles on the rover so far. I won't be using it as a DD until I have the new cooling system installed. So far the only codes I get on the Ultragauge anymore relate to the SAI that I removed. Fingers crossed nothing else will pop up. The car does seem to idle a little more rumbly than I expected on a newly rebuilt motor, but I'm sure it's still breaking in the engine as well as the ECU is still learning.
The radiator came in last night, Nissens, so that will be going in with a new 180 t-stat and all new cooling hoses this weekend. Then we will see what temps its running at.
After running the car up, it ran at 203-12 on the highway and at stops. BUT, the radiator felt very uneven on heat distribution. The top right was hot, but the rest was mostly cool. I have a feeling the old one was clogged up.
So, Friday I'll drop the new cooling system in, top it off, and then take it out and test. If I have the time, I'll do a drain and fill on the tranny and put in the new filter and gasket that came in.
Then on Sunday use it to move from my apt to the new house.
