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Got the "bad" coils out and discovered that the grounding strap from the block to the body was totally loose, so I'm guessing that was the actual cause.
Good find @mollusc ! That webbed grounding strap was corroded at the firewall and on my engine. As a replacement I made and installed a newer thicker 10AWG shielded cable.
Last edited by JUKE179r; Jul 21, 2020 at 03:49 AM.
I installed the $65 Ebay radiator and Extincts' inline thermostat. so far temps moved from 210s on the hottest days, to less than 200 in the worst scenario. I have not driven it fast enough to really see how low the temp will get at speed. The install was very simple. Abran's radiator installation directions were supper helpful, did not have to remove anything extra. Thanks for those.
I will probably cut up the radiator cover so that it all fits better.
I am not sure I have it bled correctly, keeping an eye on it. I wonder if it makes sense to tap the thermostat housing and add a bleed screw? Otherwise, it is a very good product, good instructions, no extra parts needed.
Now 100% of my cooling system is new. If anyone needs a T pipe or 180 degree thermostat with very few miles, let me know.
Picked up a set of 03/04 headlights/wiring so I can begin to do an HID retrofit for my white D2. Did the PCV mod on the new green one, oil change and new plugs. That didn't clear up the cylinder 1 misfire so coils are on order and I have new lines that I never put in the white one ready to go. Will check grounding strap to see if that's part of my issue.
@redrover75 In theory it should self bleed now as you have simplified the coolant flow. So the air should get pushed to the top of rad and through the small return hose over a few days. Just keep an eye on your coolant level.
I got a chance to drive it proper today. Its 95 outside, i never saw more than 190, prior to the thermostat and the radiator, I would have expected well over 210 when I stopped moving.
For $90 for the thermostat set up, $65 for the radiator, and a couple hours of time, thanks again to Abran's instructions, I would say that is a "real result" in the parlance of Ed. Seems to be a much more reliable cooling process as well. less to fail and no real bleeding to do. One thought I have is that it appears that the thermostat is near the high point of the system, coolant probably does not cover the thermostat unless there is pressure from the water pump. I may be wrong, or it may not matter, but this appears to be the case.
Did new coils, wires and plugs on the new disco. Was a huge pain doing it without pulling the intake but I got it all done and she runs like a champ now.
Went to replace my Low range detect switch, ordered the wrong switch. Sprayed the old one with a ton of switch and contact cleaner, and I get a the manual option on the transmission again ! But HDC still flashes so the switch is marginal at best.
Still needs replacement as it appears to be failing, but at least I can reach it.
Lubed the High low/range cable and ran it through the all positions
Last edited by Richard Gallant; Jul 30, 2020 at 01:33 PM.
Took the 04 for a ride, to charge the battery and give it some exercise. Started with one revolution of the crank and ran beautifully. Did a little seven mile drive, smooth sailing all the way...parked it back in the garage.
Replaced all my rubber mounts one was completely broken on my secondary air pump. Also found that the charcoal filter was completely clogged. Impossible part to find online so I opted for an alternative small engine air filter which was close enough fit.
