The intercooler may be responsible for some of the heating issues. It sounds as though the outside air is being heated by passing through the intercooler before it gets to the radiator. That effectively makes the air going into the radiator hotter, similar to driving a car on a much warmer day.

Is there any way to relocate the intercooler or redirect some air around it? Are you running the factory air dams and are they in good shape?

You might consider installing the "Big Mouth" air dam to get more air into the opening. Do a search on "Big Mouth" for information about this piece. It's made and sold by a Forum Supporting Vendor and it has had some good reviews for helping with cooling.

A good way to help with getting air out of the early C4 system is to raise front of the car a good 8-12 inches when filling the system. Any air pockets will rise to the higest point once they become disloged from the engine running and coolant is flowing. Fill the system, start the motor, and let it idle. Once the 'stat opens, add more coolant so that the system is full and replace the pressure cap.

Lt the motor run for 5-10 minutes unless you see high temps (240-250) If that happens, kill the motor and let it cool so you can remove the pressure cap. Check coolant level and fill as needed. You may see the Low Coolant light come on for a couple times, and that is probably small air pockets being passed to the radiator. Just kepe an eye on the coolant level and have the right amount of clean coolant in the overflow tank.

 

That's what I was gettin' at.

For each doubling of distance of hot objects from each other, the cooling capacity is increased 4 times (in theory).

 

I never knew that, cool.
I may be able to put a oil cooler up there if I can get it spaced out enough.

 

I have thought about a Big mouth, and I really should get one.

The air dam and the rest of the stuff up front are in great shape.

There is no doubt that the intercooler is a BIG part of the problem, but that is where it has to go, it is just way to big to go any where else.

I thought about using a later model C4 intercooler from ProCharger, there are two of them that mount under the headlight wells, due to the slated radiator, but I was advised against it due to poor charge cooling of that setup.

I am seriously thinking of going with a BlowerWorks meth setup and ditch the intercooler, but the bad thing is you would only get one shot at running it dry.

The way we have been filling the radiator seems to work very well.

The line that comes off the intake at the back is the highest point of the cooling system that you can get to.

After the first fill, if you take the cap off cold it is evident that the cap is not the highest point because of the amount of coolant that will come out.

I have a vacuum fill set up from Snap-On, but I have never used it on the C4, maybe I will try it next time.

Greg

 

That applies only to radiated heat, conducted heat (radiators) is different. Your radiator is receiving air that was warmed up by passing through the a/c condenser and the intercooler.

 

I use a Moroso inline filler neck to fill mine I put it in as close to the thermostat housing as possible with it at the highest point of the engine it makes it pretty easy to get the air out after a couple heat and cool cycles. It installs easy cut the top hose take 1.5 inches out of the hose slide it in and clamp it

 

I wish, blower outlet is right there, now way, the hose will barely fit.

The hose coming off the back of the intake may be different on other year models, but it is almost as high as the top of the intake plenum, so at least I have a good place to bleed it.

 

I always test a t-stat before installing because I installed a fail-safe which stuck open after putting it on. I wouldn't have minded it being stuck open if it wasn't winter.

 

You can bet we will here at the shop from now on.