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Thread: coolant capacity problem

  1. #1
    Discovery-94 Guest

    coolant capacity problem

    I just replaced my water pump (and the head) in a 300 TDI, but when refilling the system, it only took about 7 litres of coolant instead of the specified 11.5 l. Just wondering if anyone had a similar issue?
    Before refilling I flushed the block and had the radiator out to clean.
    I filled the system through the thermostat plug as described in the repair manual, and bled the system through the radiator bleed plug after running the engine briefly. Also the heater isnt working even after reaching operating temperature.
    Any tricks on finding the blockage and/or air? (and how to get rid of it?)
    cheers

  2. #2
    Join Date
    Aug 2009
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    Buenos Aires (Argentina)
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    You should bleed the system from thermostat plug, not from radiator.
    When You see fluid at radiator top, You must close radiator plug. You can then add fluid in the Thermostat housing, but until level reachs the "X" mark in the expansion tank. Not more!
    It seems your pump is not pumping trough the heater line because it is not correct bleeded.
    You can do as with a normal centrifugal pump. I saw this method from another Disco mate here: with the fluid level in the correct mark at expansion tank you keep open the Thermostat plug, (but with attention in order to screw it instantly).
    You run the engine and you will hear the air blowing until water with high pressure comes out. This is the reason i indicate attention. Tighten thermostat plug.
    Then You don't open any plug. The only you can open is the expansion tank cap, in order to top fluid level until the "X" mark.
    This will not fail!

    Good luck!

  3. #3
    Join Date
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    Sounds like an air lock somewhere. Probably in/near the heater. On some vehicles there are bleed screws even on the heater hoses. What does the temperature gauge show?
    What you can do is to take off the reservoir and elevate it above the present location (which is, unfortunately, not the highest point of the system). Then you start the engine whilst having the heater fully open and add coolant as the level lowers, taking care not to overheat the engine.

    Good luck!
    Cheers
    Johannes

    There are people who spend all weekend cleaning the car.
    And there are people who drive Discovery.

  4. #4
    Discovery-94 Guest
    thanks guys!
    i did bleed it through the thermostat, result: the heater is working now and we lost a little bit of air, but it never actually shot coolant out "under pressure"... well, coolant did flow out but.. as I said, not under pressure...
    and well, I did then raise the expansion tank, while running engine and heater, but the water did not drop (ran about half hour in total...)

    so ... I have another question as to what it could be... instead of the original black expansion tank i have the white one installed... is it possible that this one holds less water (I am up to about 8.5 litres in the system... couldnt fill anymore even after bleeding, running, and cooling down... so were missing about 3-3.5 litres at the moment....?)?

    anybody any opinion or input to that please?
    cheers!

  5. #5
    Join Date
    Aug 2009
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    Buenos Aires (Argentina)
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    The new white reservoir is approx the same as older.
    Scuse me for my bad redaction (my language is spanish), but this thing with pressure can be as you describe. I saw my mate holding the plug, heared a whistle (that could be the air trough a small gap) and my mate closed the plug quickly, with some water droping.

    And regarding the reservoir raising, I was searching in my local club forum myself describing the last time I filled the system, and i didn´t lose the mark level too...
    So Your system is now from my viewpoint ok
    There is a difference in capacity between user manual and reality, i don't know why...


    Regards

  6. #6
    Join Date
    Aug 2007
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    Mandurah WA
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    You may have blocked cores in the radiator if it was only flushed out.The water can run from top to bottom without going through the actual core.To ensure no blockages requires the tank taken off and the cores rodded.

  7. #7
    Join Date
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    Your "missing" coolant is probably the amount of water left in the block after draining the cooling system.

    Although the lower hose is the lowest part of the cooling system water can sit inside the cooling system passage ways in the block even with the hoses off. It wouldn't surprise me if you had 3 or more litres in the block that is near on impossible to drain out.

    Provided you have bled the system and the heater now works I wouldn't get too worried.

  8. #8
    Discovery-94 Guest
    Thanks everybody for your input!
    I still dont quite understand what is going on,... or hopefully WAS going on!

    I decided on Monday to re-drain the system to check the heater hoses out -and flush everything again, just in case there is a blockage somewhere... but everything seemed sweet...

    So I came to the same conclusion as bigjon, ... that there must have still been some coolant in the block,... so I re filled the system and bled it again the way I did before... until the heater worked. When I decided to take it for a test I got out the driveway, but as I got back in the car after closing the gate I just saw the temperature gauge reaching the red bit... rising VERY quickly...
    I turned the engine off immediately, and opened the thermostat plug again - and it took another liter of coolant... by this time the engine had been idling for about 25 minutes without the gauge even reaching dead center....
    Well, attempt number 2 to leave the driveway ended just as quickly, and so did attempt number 3.
    I now filled about 10 liters of coolant in the system in total and must have bled it for about 2 hours waiting for every little bubble of air to come out (partially with the front of the vehicle raised, partially with the overflow tank raise - which didnt seem to make any difference thoughd)....
    I let it cool down completely and filled the thermostat housing up again before starting - and it runs fine now.... heater working well and no overheating even on my test drive...

    Only other thing i found was that the gauge must be screwed... or at least the sensor - it had these sudden fluctuations from just under dead center to red hot and back every now and then... could have been the air coming through, but I dont trust it! I replaced the thermostat housing with a second hand one, so I will get onto changing the two switches over this afternoon...

    Thanks again for everyones answers!!
    cheers

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