I wanted to share my experience & advice with overhauling the cooling system. It was straightforward overall (except re-brushing the aux pump)
A connection on the overflow tank broke off and spewed coolant all over my face, and i decided it was time to flush and service the coolant system. Car has 84k miles, coolant is thought to be original.

I replaced:
Thermostat, waterpump, overflow tank, rebrushed aux pump, and flushed heater core.

I bought stant 14748, which is identical to the OEM one i pulled.




Water pump was Airtex AW4124. The design was slightly different than oem which was a 2 piece design and had a metal gasket. There was a TSB attached to new water pump stating the one piece design is current, superseding the old design.




water pump & thermostat are very easy to get to and install.

The hard part was rebrushing the aux pump.
Soldering the new brushes was easy, I had to grind off about 1/8" or so so the brushes fit.

As other people have discovered, theres no way of preloading the brushes and re-assembling the motor.


My solution was to use some fishing line to hold the springs back allowing the motor head to be inserted correctly. Once inserted, I simply pulled the fishing line out. It took a couple tries to figure it out, but i finally got it.

I used boiling water & citric acid to flush my heater core. I did 3 applications, blowing out the solution with compressed air after.

Heres the progression of my flush, I followed advice from here which describes a drain/fill/drive with distilled water 3-4 times, then adding coolant at end.



I never had to jack up front of car or open the large hex head port near the intercoolers to properly bleed the system. the aux and sc pumps are effective in priming the system.

 

Sounds like a well done job.

Every time I have taken out the hex nut on the SC coolant top up port coolant has been up to the correct level.

So for me that was a waste of time plus I damaged the washer under the nut! I was never able to find a correctly sized "felt" washer and have had to use sealant which works just fine.

 

I never bleed the system with the hex nut.
I raise the front by driving up on car ramps. Then its just a simple matter of running the pups to bleed the system. The key here is to have the reservoir higher than the intercoolers allow the air to accumulate in the reservoir

Cheers
34by51

 

I recently replaced the supercharger pump and drained the coolant system,
I measured exactly what came out, put back the same amount. I had no trouble getting the same amount back in and air out of the system without raising the front of the car or removing the SC vent plug. Just ran the SC and aux heating pumps to vent the system and filled via the reservoir.