DRAINING & REFILLING COOLING SYSTEM
WARNING:DO NOT remove expansion tank filler cap when engine is hot. The cooling system is pressurized and severe personal injury could result.
Draining Cooling System (Discovery Series II)
Allow cooling system to cool for several hours. Visually inspect engine and cooling system for coolant leaks. Examine hoses for signs of cracking, distortion and good connections. Perform repairs as necessary. Position drain tray to collect coolant. Remove expansion tank filler cap.
Remove left and right drain plugs from sides of cylinder block. Disconnect bottom hose from radiator and allow cooling system to drain. Disconnect top hose from thermostat and position open end of hose below level of water pump intake, to allow coolant to drain completely from cooling system. When cooling system repairs are completed, go to REFILLING COOLING SYSTEM (DISCOVERY SERIES II).
Refilling Cooling System (Discovery Series II)
CAUTION:Cooling system expansion tank filler cap relief valve opens at 20 psi (1.4 kg/cm2 ). Exceeding cooling system operating pressure when flushing cooling system may damage radiator.
Using water under low pressure, flush cooling system. Apply Loctite No. 577 to threads of cylinder block drain plugs. Install drain plugs to cylinder block and tighten to specification. See TORQUE SPECIFICATIONS. Connect bottom radiator hose to radiator and top hose to thermostat housing.
Release upper radiator hose from retaining lugs on the fan cowl, leaving hose to rest on lugs and connected to radiator. Remove bleed screw from middle of upper radiator hose. Release coolant expansion tank overflow hose from battery box. Remove expansion tank from its mounting bracket. Slowly fill the expansion tank with approximately 4.2 Qts. (4.0 L) of coolant. Raise expansion tank up approximately 8 inches until coolant begins to drain into the cooling system.
Refill coolant expansion tank until a steady flow of coolant is discharged from the bleed hole. Install bleed screw then. With expansion tank still raised, continue filling cooling system until coolant level reaches the base of the coolant expansion tank filler neck. Install coolant expansion tank filler cap and remount expansion tank and overflow hose.
Install top radiator hose into lugs on the fan cowl. Start engine and allow to idle until normal operating temperature is reached. Monitor temperature gauge to ensure engine does not overheat. Check cooling system for leaks. Turn engine off and allow to cool. Recheck for leaks and refill coolant to COLD LEVEL mark on expansion tank.
Sunday, August 9th, 2009 AT 7:18 PM