cornish rattler · May 15, 2023

Hi guys
What is the best way to refill the cooling system using a 200tdi radiator with a 300tdi header tank

I have just replaced my bottom hose and re-routed the hose from header tank to a T piece to one of the heater pipes and when refilling the system with fresh antifreeze and water i filled the header tank to the half full seam of the tank and ran the engine at idle for just over an hour to allow it to get to normal temp then left over night to cool down and re-checked the level in the morning which really didn't go down much, then later i went for a 100 mile jaunt and when i came back the header tank was very low just and covering the top of the two hose necks of the header tank

Any idear's please

Bobsticle · May 15, 2023

Eye through your engine bay at the level the coolant ended up at.
Anything coolant related above this level is suspect for a leak.

My series drove me mad with the coolant level continuously dropping just past the fins in the rad.
Until I discovered a split in the heater pipe near the matrix.

cornish rattler · May 15, 2023

Bobsticle said:
Eye through your engine bay at the level the coolant ended up at.
Anything coolant related above this level is suspect for a leak.

My series drove me mad with the coolant level continuously dropping just past the fins in the rad.
Until I discovered a split in the heater pipe near the matrix.

Yeah i've checked for leaks and can't find any, but what got me thinking is i saw a youtube vid last night ok of a different animal a td5 engine converted into a disco 1 where they used a tdi rad and 300tdi header tank and after filling the rad they just filled the header tank to more or less the top and test drove it but it didn't show the header tank afterwards

Bobsticle · May 15, 2023

I couldn’t find a leak either. That’s why it took me a year to come across the split.
Must have only happened when driving.

cornish rattler · May 15, 2023

Bobsticle said:
I couldn’t find a leak either. That’s why it took me a year to come across the split.
Must have only happened when driving.

Arw ok

v8250 · May 15, 2023

Fill system as per normal through top of radiator with header tank cap off and heater matrix fully open. With engine running squeeze through system between top & bottom hose, top up if necessary. Then take for a gentle short drive at full operating temperature, back home and top up if needed. Then keep an eye on levels for leaks. I also find when filling any car coolant system to measure out the volume required and pour in slowly as this confirms if there's an air blockage as not all the coolant can be poured into the system :. a 2-3 stage fill.

lynall · May 15, 2023

cornish rattler said:
Hi guys
What is the best way to refill the cooling system using a 200tdi radiator with a 300tdi header tank

I have just replaced my bottom hose and re-routed the hose from header tank to a T piece to one of the heater pipes and when refilling the system with fresh antifreeze and water i filled the header tank to the half full seam of the tank and ran the engine at idle for just over an hour to allow it to get to normal temp then left over night to cool down and re-checked the level in the morning which really didn't go down much, then later i went for a 100 mile jaunt and when i came back the header tank was very low just and covering the top of the two hose necks of the header tank
Any idear's please

200 as follows
Fill rad via the top plug, when full refit top plug, fill header tank until it is correct (look in and you will see a plastic cross) refit header tank cap, and this is the important bit, remove the stat housing top plug and continue filling with coolant until full, refit plug, job done.
Failure to fit header tank cap will mean all the coolant you put in the stat housing will go to the header tank and leave a massive air lock at the cyl head, this is what potentially fek the head as until the stat opens there is no coolant.

My s2 tdi runs the std s2 rad.

cornish rattler · May 15, 2023

lynall said:
200 as follows
Fill rad via the top plug, when full refit top plug, fill header tank until it is correct (look in and you will see a plastic cross) refit header tank cap, and this is the important bit, remove the stat housing top plug and continue filling with coolant until full, refit plug, job done.
Failure to fit header tank cap will mean all the coolant you put in the stat housing will go to the header tank and leave a massive air lock at the cyl head, this is what potentially fek the head as until the stat opens there is no coolant.

My s2 tdi runs the std s2 rad.

No plug in thermostat housing, its a Defender 200 tdi dressed as a Disco 200tdi but using the Defender thermostat housing if it helps

Bobsticle · May 16, 2023

Think yourself lucky. I went with a water free coolant last year after the engine rebuild. I’m paranoid about losing coolant at those prices.
Not sure if it makes any difference in the original two and a quarter diesel but l thought at least it would keep the internal rust down. Not sure if it is as it still looks a tad red in the radiator.

cornish rattler · May 16, 2023

Bobsticle said:
Think yourself lucky. I went with a water free coolant last year after the engine rebuild. I’m paranoid about losing coolant at those prices.
Not sure if it makes any difference in the original two and a quarter diesel but l thought at least it would keep the internal rust down. Not sure if it is as it still looks a tad red in the radiator.

Yeah i was toying with the idea of going that way when i was doing the rebuild but decided against it.

cornish rattler

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