Koyo Radiator + Flex-a-lite fans in 04 RSTi swap

2.5RSMatt · 11-05-2008, 08:58 PM

I'm trying to install a Koyo Radiator + Flex-a-lite fans into an 04 RSTi swap, but I'm running into clearance issues, particularly with the fans. The fans seem way too close to the crank pulley and the header heat shields also seem to be in the way.

I have attempted to install the radiator with fans attached but that did not work and so I took off the fans and installed the radiator. Still, the fans will not wedge into position and I'm clueless as to how to make them fit with safe clearance.

Any help is appreciated.

-Matt

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Jaxx · 11-06-2008, 11:50 AM

do you still have the AC?

i had to use pusher fans..

or use the legacy turbo fans ..

2.5RSMatt · 11-06-2008, 12:46 PM

I do still have AC although it doesn't work currently but I'd like to keep it.

I think I may have found a solution but I'm not sure it's the best. I removed the backing plates off the fans (they're more like plates with logos on them) which bought me about 1/4 in of more room. I'll take some photos so you can get an idea of what I'm talking about.

ciper · 11-07-2008, 04:55 PM

Is it touching the pulley and heat shield or just very close? I've worked on two cars that have the Koyo rad and the stock plastic fans. The lower passenger side leg of the fan melts slightly but there is no other issue with the engine rocking into the fans.

NickWRX · 11-07-2008, 07:19 PM

YEah ive heard that in our cars with swaps, the koyo with stock fans hits. I have heard the flex a lite gives you almost enough. I went throug nearly every friggin resource possible. Im talking shops, other owners, stores, etc. etc. and NO ONE had any solution!!!

My solution, I went with a stock Koyo. It works just fine and cooling is never an issue. Sell that setup and make a ton of money back!

But I have heard you could try and have someone rebend some of your ac lines so that they will clear. Not sure tho, good luck on the IMPOSSIBLE WORLD OF GC8 SWAPPED CARS AND THEIR RADS!!!

2.5RSMatt · 11-08-2008, 03:07 AM

Thanks for the replies.

I took off the backing plates and got the radiator and fans to fit. The stock header heat shields were causing a problem so I had to remove the center portion of the header to install the rad/fan and then reinstall the header. I never realized how little room there was to work on this motor in this chassis.

Everything is cool now except the car won't start

All accessories work but it won't turn over.

powerneedy · 11-09-2008, 07:49 PM

we had a koyo rad and flex fans and had tons of room... we have the stock sti rad with stock fans in our swap now and still have room in our 95

11-05-2008, 08:58 PM	#1
2.5RSMatt Scooby Specialist Member#: 30497 Join Date: Nov 2002 Chapter/Region: SCIC Location: San Diego, CA Vehicle: 00 RSTi FUK HDR	Koyo Radiator + Flex-a-lite fans in 04 RSTi swap I'm trying to install a Koyo Radiator + Flex-a-lite fans into an 04 RSTi swap, but I'm running into clearance issues, particularly with the fans. The fans seem way too close to the crank pulley and the header heat shields also seem to be in the way. I have attempted to install the radiator with fans attached but that did not work and so I took off the fans and installed the radiator. Still, the fans will not wedge into position and I'm clueless as to how to make them fit with safe clearance. Any help is appreciated. -Matt * Registered users of the site do not see these ads.

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11-06-2008, 11:50 AM	#2
Jaxx NASIOC Supporter Member#: 177 Join Date: Aug 1999 Chapter/Region: NWIC Location: Boise,Idaho,USA Vehicle: The 93 Imp W/EJ20K flat black	do you still have the AC? i had to use pusher fans.. or use the legacy turbo fans ..

11-06-2008, 12:46 PM	#3
2.5RSMatt Scooby Specialist Member#: 30497 Join Date: Nov 2002 Chapter/Region: SCIC Location: San Diego, CA Vehicle: 00 RSTi FUK HDR	I do still have AC although it doesn't work currently but I'd like to keep it. I think I may have found a solution but I'm not sure it's the best. I removed the backing plates off the fans (they're more like plates with logos on them) which bought me about 1/4 in of more room. I'll take some photos so you can get an idea of what I'm talking about.

11-07-2008, 04:55 PM	#4
ciper Scooby Guru Member#: 15543 Join Date: Feb 2002 Location: san francisco, ca Vehicle: 90BJ Legacy LS ABS AWD 946 Rio Red Jpn built	Is it touching the pulley and heat shield or just very close? I've worked on two cars that have the Koyo rad and the stock plastic fans. The lower passenger side leg of the fan melts slightly but there is no other issue with the engine rocking into the fans.

11-07-2008, 07:19 PM	#5
NickWRX Scooby Newbie Member#: 15948 Join Date: Mar 2002 Chapter/Region: Tri-State Location: Warrington, PA Vehicle: 2001 2.5RS 317awhp-277ft./lb	YEah ive heard that in our cars with swaps, the koyo with stock fans hits. I have heard the flex a lite gives you almost enough. I went throug nearly every friggin resource possible. Im talking shops, other owners, stores, etc. etc. and NO ONE had any solution!!! My solution, I went with a stock Koyo. It works just fine and cooling is never an issue. Sell that setup and make a ton of money back! But I have heard you could try and have someone rebend some of your ac lines so that they will clear. Not sure tho, good luck on the IMPOSSIBLE WORLD OF GC8 SWAPPED CARS AND THEIR RADS!!!

11-08-2008, 03:07 AM	#6
2.5RSMatt Scooby Specialist Member#: 30497 Join Date: Nov 2002 Chapter/Region: SCIC Location: San Diego, CA Vehicle: 00 RSTi FUK HDR	Thanks for the replies. I took off the backing plates and got the radiator and fans to fit. The stock header heat shields were causing a problem so I had to remove the center portion of the header to install the rad/fan and then reinstall the header. I never realized how little room there was to work on this motor in this chassis. Everything is cool now except the car won't start All accessories work but it won't turn over.

11-09-2008, 07:49 PM	#7
powerneedy Scooby Newbie Member#: 161242 Join Date: Oct 2007	we had a koyo rad and flex fans and had tons of room... we have the stock sti rad with stock fans in our swap now and still have room in our 95