Filling Your Cooling System - Defender Source
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  #1  
Old July 12th, 2006, 01:47 PM
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Christian Gunther
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Filling Your Cooling System

This may be a basic question, but I have seen several references to a correct method for filling your cooling system. Could someone(s) do a step by step for me?

Thanks.
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  #2  
Old July 12th, 2006, 01:52 PM
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Remove the black plastic plug in the heater lines on the RH side of the engine (tall pipe that sticks up above the RH valve cover)
Remove the black plastic plug on the RH side of the radiator (vehicle RH side) and remove the cap off the expansion tank.

Fill with proper coolant mix at the radiator plug until fluid comes out the heater plug.

replace the heater line plug, replace the radiator plug and top up the expansion tank to the proper level.

That way no air bound issues. Factory way of doing it.
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  #3  
Old July 12th, 2006, 02:25 PM
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At any point, is the engine running?
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  #4  
Old July 12th, 2006, 02:28 PM
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Nope, not until everything is full and closed. Then run it up to temp and top the expansion tank if needed. Usually won't need any.
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  #5  
Old July 12th, 2006, 09:20 PM
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How about for a 300TDi?
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  #6  
Old July 12th, 2006, 09:39 PM
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Jack Walter
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There are also two plugs on a Tdi - basically same procedure - replace both of the plastic plugs as soon as possible with the brass ones though - the plastic one on the radiator of my RRC popped last weekend.
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  #7  
Old July 12th, 2006, 10:05 PM
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Quote:
Originally Posted by ronward
How about for a 300TDi?
This is a highly difficult process and I don't recommend the average weekend wrench try it.

Step 1: Remove Reservore cap
Step 2: Open Beer
Step 3: Fill with coolant
Step 4: Drink Beer
Step 5: Replace cap
Step 6: Check level later
Step 7: Repeat steps 2 and 4

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  #8  
Old July 13th, 2006, 07:04 AM
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That's just two beers lightweight.

Jack, The Coop's got a brass plug in the top of the radiator already. There's another plastic plug someplace?

Thanks for the help!
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  #9  
Old July 13th, 2006, 08:22 AM
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Yup, hes dead one. The plastic plugs suck.
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  #10  
Old July 13th, 2006, 11:59 AM
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Mine has another plug right behind the thermostat housing - sorta near the oil filler cap - I replaced that one too. It's at the high point in the cooling system so that you can bleed the air out.
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  #11  
Old July 13th, 2006, 11:39 PM
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One more thing guys. On a 300 Tdi I'm assuming there is a lip on the thermostat housing to align the housing/hose connector to the actual block. If this is not true how do I avoid getting excess RTV gasket maker oozing into the waterway and into the engine? May be elementary school here, but I've not changed a thermostat in years, and never on this engine.

Thanks!
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  #12  
Old July 13th, 2006, 11:59 PM
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Quote:
Originally Posted by ronward
One more thing guys. On a 300 Tdi I'm assuming there is a lip on the thermostat housing to align the housing/hose connector to the actual block. If this is not true how do I avoid getting excess RTV gasket maker oozing into the waterway and into the engine? May be elementary school here, but I've not changed a thermostat in years, and never on this engine.

Thanks!
You really shouldn't have to use any silicone. If my memory is correct, its an unscrew, screw and thats it.
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  #13  
Old July 14th, 2006, 03:30 PM
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Hey Guys,


Where do you buy the brass filler plugs?
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  #14  
Old July 14th, 2006, 03:38 PM
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I bought one from EE for 30 i think it didnt work, couldnt screw it in by hand so I didnt wanna fuck with it. ordered another plastic one from Rovers North went in with ease. the one from EE looked used etc. not sure if it might have been a bad batch of plugs or what.
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  #15  
Old July 14th, 2006, 04:19 PM
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I bought some from the guys at DAP at the MAR event last fall - around $16 each if I remember correctly.
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  #16  
Old July 14th, 2006, 04:33 PM
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Johnathan Tisdale
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Napa for less than $2
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  #17  
Old July 14th, 2006, 05:41 PM
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Quote:
Originally Posted by WhiteD90
Napa for less than $2
You have to be extremely careful with that one though. It is recommended that you cut a circle out of a $20 bill to use as a gasket to make it more like a "genuine" one.
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  #18  
Old July 17th, 2006, 06:34 PM
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Quote:
Originally Posted by ECR
... top up the expansion tank to the proper level.
Maybe this is a stupid question, but why does there need to be coolant in the expansion tank?
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  #19  
Old July 17th, 2006, 08:18 PM
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there doesnt
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  #20  
Old July 18th, 2006, 08:42 AM
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Yes there does (nice english).

Wide variations in temps mean expansion of the fluid. The expansion tank helps maintain the correct level in the engine so that air pockets and such do not develop (especially important on a Rover V8). Without it you could easily get the engine air bound and in the Rover system there would be no way to easily check or add coolant without the expansion tank as the radiator does not have a radiator cap like an older car.
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