192º Thermostat - Parts Diagram/dimensions added page 1

papaindigo · **Posted:** Wed May 18, 2011 6:58 am

Based on all of kap's tstat string and what he shipped to stoutdog that has been installed and is running my take on the parts is as follows. Water Outlet 98-01 Kia Sephia 1.8L DOHC; Thermostat 195 or 180 (Stant 35979-195 or 48469-190 others are available - NOTE looking back thru the string kap prefers MotoRad tstats) 95-99 Hyundai Accent 1.5L DOHC or SOHC (same); and Radiator Hose (upper) 93-97 Dodge Intrepid (Gates 22000 cut to length) 3.3L

fastRob · **Posted:** Fri May 20, 2011 9:15 am

I appreciate your position Mark, family and work come first.
This project is really fresh in my mind. Since I sent you my new thermostat to modify last July, just ordered another, getting close to 98k miles. I hear the new thermostats are a little hotter, so we shall see. Got to get that timing belt done.
Still hopeful that you sell your house, keep the wife and kids happy and do not lose your mind :wink:

kapalczynski · **Posted:** Sun May 29, 2011 1:51 am

fastRob wrote:

I appreciate your position Mark, family and work come first.
This project is really fresh in my mind. Since I sent you my new thermostat to modify last July, just ordered another, getting close to 98k miles. I hear the new thermostats are a little hotter, so we shall see. Got to get that timing belt done.
Still hopeful that you sell your house, keep the wife and kids happy and do not lose your mind :wink:

Yeah, sorry...Accent. got a bit mixed up. don't have any of my specs, ect w/ me here.

Thx for the understanding.

- Mark

P.S. for all of you...I will be in Texas for training till July 8th, but available through email at mark.kapalczynski@yahoo.com or through the forum here. We'll be heading home on the 8th of july and selling the house. Hopefully it will sell around august time frame adn we can slose in september. At the earliest I can go to Australia 10 august (early report time period) and at the latest we will be in australia will be 10 October to start my job.

turbobike · **Posted:** Fri Jun 17, 2011 4:19 pm

Did Rooster take on this project ?
I just had my thermostat replaced, so I have a thermostat housing to donate to the cause.

Also replaced the water pump. Pump appeared to be in very good condition. No play in the shaft and the impeller appeared OK--no cracks or missing fins, or signs of wear.

yakers · **Posted:** Fri Jun 17, 2011 10:40 pm

turbobike wrote:

Did Rooster take on this project ?
I just had my thermostat replaced, so I have a thermostat housing to donate to the cause.

Also replaced the water pump. Pump appeared to be in very good condition. No play in the shaft and the impeller appeared OK--no cracks or missing fins, or signs of wear.

How many miles on the water pump? Some folks seem to get <50K miles and others are past 100K miles with no problem. I have 90K miles and plan to replace it and the TB in the next 10K miles.

turbobike · **Posted:** Sat Jun 18, 2011 8:04 am

100,453 miles on the water pump. I think if I was doing a timing belt change, I would definitely do the water pump too, because of the labor & time spent going that far into the engine. To not do it...and then have the pump fail a short time later---would be extremely frustrating (and expensive)
Just my 2 cents.

geordi · **Posted:** Sat Jun 18, 2011 6:07 pm

Doing the job yourself, you realize it really isn't that far into the engine, and doing the water pump is a major PITA. If you dig into the system and get the front cover off, look and feel each of the pulleys - The bearings will discharge grease and howl when they fail... If everything is clean and smooth, solid feeling... Then they are good to go.

The bearings are the same as any accessory belt bearing, and while the accessory belt isn't as critical an item certainly... Have you heard of a lot of accessory pulleys failing? Not so much.

I'm over 110k now, rapidly closing on 115, original water pump from this engine.

dgeist · **Posted:** Sat Jul 16, 2011 8:26 am

Mark, hopefully training went well. Any updates for the group now that the clock is counting down to OZ?

Hopefully the batch that's in-progress will find it's way up the priority list a little before the big move...

Dan

kapalczynski · **Posted:** Tue Jul 26, 2011 6:37 am

Back from training. House has been on th emarket about 2months and only 5 showings and no offers. Market isn't as good as we would like. We're doing home imporvements (staining fence, etc) to improve look to get more nibbles. Debating on reducing price a bit. Unfortunately house is keeping us pretty busy. We've decided to stretch out the time here we have as long as possible to give us more time to sell, etc. We plan on trying to get a port date (date we leave country) of around 1 Oct if we can push it back that far. May or may not get this batch done, alot of house stuff hanging over our heads.

On another note, I saw a CRD liberty in San Angelo, TX while i was ther for training. and on ANOTHER note I saw MY EXACT CRD Liberty - same Turbodiesel emlems, had my foglights and mud flaps, etc - MY old CRD at Schriever AFB last week.

Really made me miss her. Had I known I would be going overseas to Australia where gas is $6.50 US a gallon, and my Jeep grand cherokee is lifted too high to register for a vehicle on the roads there, I definately would have kept her.

We are planning one last hurrah for my Grand cherokee up Mt Blanca trail in Colorado before we sell her. Hate to let her go, but doesn't make much sense to keep her either. I am really torn, I love that vehicle so much. If I keep it, I will keep it in the states and park it.

I talked to Keith at Green Diesel Engineering recently. I keep bugging him to do a tune for the VW TDI Jetta's so I can get one. LOL I really like the work he has done and hes a great guy, great customer service.

Anyway good to chat w/ u all, really really hope we get an offer on the house and things can start winding down so I have time to work on these units.

You all can shoot me an email at awdv8@yahoo.com if u need something or just wanna catch up.

- Mark

kapalczynski · **Posted:** Tue Jul 26, 2011 6:41 am

turbobike wrote:

Did Rooster take on this project ?
I just had my thermostat replaced, so I have a thermostat housing to donate to the cause.

Also replaced the water pump. Pump appeared to be in very good condition. No play in the shaft and the impeller appeared OK--no cracks or missing fins, or signs of wear.

I would recommend sending the core to Roostre if you can work it out w/ him. I plan on sending him stuff to get started, etc. Shoot him a PM and see if you can get it worked out. I haven't duplicated the pressure test setup yet to send it to him, but it should be easy enough to do before I leave for Australia. Also gonna send him specs, etc I have. I really need to call him and catch up.

fastRob · **Posted:** Sun Aug 07, 2011 9:56 am

Mark,
The mechanic broke my new thermostat during timing belt replacement.
Any chance you could send me a/my thermostat as it is.
I will pay you for what you have done.
Have a good local machinist.
Thanks,
Robert

kapalczynski · **Posted:** Mon Aug 22, 2011 10:58 pm

fastRob wrote:

Mark,
The mechanic broke my new thermostat during timing belt replacement.
Any chance you could send me a/my thermostat as it is.
I will pay you for what you have done.
Have a good local machinist.
Thanks,
Robert

Unfortunately it is already in process, top cut off, etc, so wouldn't do u much good unless u want to finish it yourself. Looking back on things i shouldn't have started on the new units that people bought from factory till last minute, but it didn't go that way as i was trying to mass produce a bit in groups. If you want it back at the stage I have it I am happy to send it at no cost to you and wouldn't expect you to pay for my time or shipping etc. If you want some of the other parts I will get them to you at my cost (thermostat housing/thermostat, gasket, etc).

Sorry for the delay on this, i am not on here as much as I would like to be.

Please email me at mark.kapalczynski@yahoo.com if you need something fast.

- Mark

kapalczynski · **Posted:** Mon Aug 22, 2011 11:06 pm

Just an update for you all.

I just used up the last bit of 3" x 1/2" wall aluminum round tube stock I have and ordered the last bit of it I need to finish this all up. I believe I should have enough inventory of everything else now to finish all the cores I have. I just haven't had alot of machine time available. I got several hours in today thankfully though. Got 12 more of the intermediate plates machined, still need to drill the mount holes though. Started on some more press in inserts also.

I need to go through my inventory and see for sure how many sets of radiator hoses, thermostats, brass pieces, hardware, studs, water necks i have. Should be around 25 sets of everything I think.

Catch u all later. Been busy, but workin days and have some time here and there after work to do machining so hoping HOPING to get this all done.

We are going to get 1st or 2nd of October for our port date (date we leave country). We haven't sold the house yet and just listed the Jeep to sell. We have a buyer lined up for the second car.

House is cleaned up and ready to sell, just need to maintain the lawn, etc till it either sells, or we leave.

As mentioned, i will do my best to get done w/ what i have here.

If you need anything please don't hesitate to contact me at mark.kapalczynski@yahoo.com or on facebook w/ that email to look me up. If you need a phone number to chat shoot me a email please since I am not on the forum as much as i'd like to be.

- Mark

dgeist · **Posted:** Tue Aug 23, 2011 8:45 am

Thanks for the update Mark. I was hoping to get the assembly before the trek to ECS (second weekend in October). Sounds like you'll either be done with the batch by then or you'll be on a slow boat to Oz with more important things to think about.

Glad things are all falling into line and hope the house sells for you.

Dan

CATCRD · **Posted:** Tue Aug 23, 2011 6:10 pm

Yes, thanks for checking in. I would love to get mine before the cold weather sets in in CO.

fastRob · **Posted:** Tue Aug 23, 2011 11:38 pm

Yippee!!!

grywlfbg · **Posted:** Wed Aug 24, 2011 3:07 pm

Yep, thanks for the update. I'm impressed you're able to find time to work on our stuff w/ all the other stresses you have going. We really appreciate it.

kapalczynski · **Posted:** Fri Aug 26, 2011 10:05 pm

The 2" x 3" aluminum came in today, gonna try to get at it again Monday and get the rest of the intermediate plates complete.

Just found out today my wife's passport may not be complete in time. GRR lol hopefully it will, or i will have to travel there w/o her and her come later.

Had a showing of our house today and have one tomorrow. I really hope and pray it sells soon! These are the first showings since we got back from training in texas about a month and a half ago.

Laters, and i'll post as i get things done,

:JEEPIN:

Mark

kapalczynski · **Posted:** Tue Aug 30, 2011 12:13 am

Rushing it a little bit with the parting tool, but cuts alot faster than the saw. LOL

All in all, a good days work. Got all the pieces cut and I have enough to do all the cores i have here.

I have about 13 of the intermediate plates machined, so half way done there.

Next is machining the rest of the intermediate plates, then all the inserts. Inserts are to the new specs of .22" thick to account for the thicker gaskets.

- Mark

papaindigo · **Posted:** Tue Aug 30, 2011 7:13 am

Such a pretty sight.

192º Thermostat - Parts Diagram/dimensions added page 1

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