Placing header tank & coolant hoses

Yesterday (6-10-2006) I went shopping at the autoparts store and some junkyards, and bought me this:

From left to right: 15 and 8 mm hose with clamps, corners and T-pieces. Two bleeding screws from two old peugeot 205’ers, a 15-8-15 mm T piece from an Alfa Romeo 33 and a heater hose valve form a Honda Civic ( I think..). I intent to use the two bleeding screws for the heater matrix under the rear seat. I am not sure yet if I’m going to use the heater hose valve. I am thinking of using it as a winter/summer switch. I am afraid the heater matrix will deliver heat even when the fan is not on.


I also connect the engine-part of the heater lines, I am routing them along the right side of the car. Because of that I had to guide hose that goes on thermostat to the right. I did this by using the 15 mm corners:

Here is also a 15-8-15 mm T-piece in it. This is for the airbleed-hose that goes to the throttle body.

edit 15-10-2006: I routed the heater hoses along from the right side of the engine, crossing over the gearbox to the old left warm-air inlet:

The bracket will keep the hose from hitting the gearbox.

Here the hoses enter the cabin through the left old hot air channel. The aluminium piece is a heat-shield which will shield the gas-filter from getting hot from the hoses.

The heater is connected. I put two air-bleed screws in the hoses. These are a high point in the system so I must be able to bleed the air out of it. I also placed a valve in the feed-line, it’s hard to see in the picture because it is partially hidden by the other heater hose. I want to connect the valve via a bowden cable to the original VW beetle heater lever.

edit 18-10-2006:
I connected the heater valve to the original left heater-lever (one of the two next to the emergency brake handle). I connected a piece of bowden cable from the Alfa heater system to the original cable:

Yeah, it’s a fussy picture. It’s the place where the bowden cable exits under the back seat. On the right is the Alfa cable. The outer cables are joined together by a strip of aluminium attached with some fuel hose clamps. The inner cables are joined by a little thingy with screws….( I don’t know how to call it….)

That cable leeds to the valve:

Now I can adjust the amount of hot water that goes to the heater matrix while driving.

edit 02-02-2006:I have a header tank from a Volvo 440, this header tank is nicely square and flat. I wanted to place the header tank as high as possible, because it should be the high point in the system. Because I have added the rear parcel shelf space to the engine room, I have enough space to place the header tank. It sits in the right front corner of the box:

I had to make a bracket for it, that has yet to be painted in these pictures. The tank is hardly noticeable when seen from behind:

This Volvo header tank didn’t have a 8 mm connection under the waterline. So I put a T-piece in the 15 mm fill hose, the breather line will be connected to the T-piece.


  1. Hi Gerrelt,
    Ik zou heel graag van je willen weten waar je die 2 ontluchters, die je in de dikke kvs slangen hebt geplaatst, hebt besteld. Loop nu al een paar uur te googlen maar kom niet achter de juiste zoekterm blijkbaar.

    Met vriendelijke groet,

    • Hoi Wynand,

      Die heb ik van de sloop gehaald, ze kwamen van een Peugeot 205, als ik het goed heb.
      Volgens mij was de slang langer, en heb ik het ontluchtingsstukje daaruit gesneden.


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