Cooling system

Leaf motor is liquid cooled, so is the inverter and charger. I will route the hoses so that liquid will flow through all of them in a loop before it ends in radiator.

This is my radiator. I got it from salvaged Fiat Panda. Its best feature is that it is very narrow and i can fit it just behind AC radiator. Second usefull feature are narrow pipes. They are 1″ pipes and with some effort i found suitable hoses to fit over the pipes and then easily reduce to 19mm as the pipes are over the motor and charger. It also has integral pressure equaliser.

Inverter has its own end hoses. I will just connect them from that end.

Water pump i will use VW Golf aux pump P/N 1K0965561J. It is easy to install in any car.

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I got it from ebay here: https://www.ebay.co.uk/itm/1K0965561J-Auto-Auxiliary-Cooling-Water-Pump-For-Passat-Golf-Audi-A3-2004-2014/273908912334

I use various hoses to connect motor, inverter, charger and pump to radiator. There was a problem with fitting a hose on Leaf motor. One fitting was just under the battery box and i had to cut it down and use a 90deg bent hose to clear the box. Otherwise there was no problems.

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I installed the radiator on two M8 studs with rubber heads. I cut the heads so they are accepted in radiator slots. From the top side i prepared one alu fitting to hold the radiator in position. This fitting is bolted to crossmember that holds battery box.

fixed the hose from charger to the front. I also needed to connect the coolant tank to the hose system and this Y adapter will be great help.

From brass tube i made a receptacle for Pug original coolant thermistor. This sensor is needed to satisfy ECU engine temperature is within limits.

While i was mounting the coolant hoses i also fixed the AC expansion tank in place. Couple of alu bands did the job nicely.

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