Radiator installation - issue with short/long drain plug options

[hell yes]

Just finished installing and I had a leak at the passenger side bottom plug.

I bought a Nissens radiator from Pelican - it came with two extra sets of plugs.

Unlike the OEM, it has a plug on the passengers side too - the enclosed diagram from nissens stated that long plug was needed for aftercooler.


I did NOT change out either of the lower plugs that came installed in the radiator as the wagon is an automatic and (I believed at the time) not after cooled…


From the diagram included I have assumed that the manual = short / Automatic = long plugs go on the driver’s side of the radiator.

From the diagram I also assume that the ‘without aftercooler’ short / ‘with aftercooler’ long plug goes on the passenger side.

(see photo “diagram” - hosted by pelican parts... thanks!)

https://cdn2.pelicanparts.com/more_info/Customer_Comment_Images/1600723180-42744.jpg


The passenger side is where I am having a leak.

(see photo“leak point”)

I had assumed I do NOT have and aftercooler - because I do not have a turbo - I’m now thinking I may be wrong in this assumption.


The enclosed diagram labels the angled radiator port as ‘aftercooler connection”

(see photo“diagram”)

I DO have a hose attached to this port.

(see photo “radiator port”)

Thinking this may be the issue, I removed the existing short plug and greased the include long plug and inserted it.
I met some strong resistance at the final ¼ “ and was not able to fully insert the plug housing.
Looking up the opening I could see the lithium grease at the very top of the plastic, just before the aluminum grills.

(see photo“view of drain opening”)

Not wanting to force it I stopped and am writing this.

I did grease the plug o-rings with white lithium grease. The accompanying directions state “before installing the long bottom plug, you should apply silicone or acid-free oil/grease to the o-rings”.

Questions:


Am I right that I need to install the longer plug (with an upper AND lower o-ring) as I have a hose attached to the “after cooler’ port?
Should there be considerable resistance as the upper o-ring seats in the radiator? Maybe I just didn’t have it well aligned?
Could the lithium grease just not bet ‘lube’ enough?


Thanks for any thoughts!

[hell yes]

Just checking back in for anyone with the same question.
info also good for the long/short plug with manual or auto w/ cooler.


Short plug has ONE o-ring at about the midpoint - it is just above the hose port and blocks it from getting fluid to the auto cooler or the 'aftercooler' (or leaking fluid if you do NOT have a hose).
Long plug has TWO o-rings at top and at bottom - bottom is below the hose port and prevents fluid from hose to leak out onto the ground, top is above the hose port and closes the main opening into the radiator but I believe clears a smaller opening to regulate flow.

SO:
if you have a hose connected to the port (either the auto cooler or the 'aftercooler')
the short plug will not block the drain area (no lower o-ring)m and so the radiator will slowly leak as fluid back fills from the connected hoses - a slow but bad thing...
the long plug will block the drain area from back flow leakage, and the top o-ring will somehow regulate fluid for the aforementioned coolers keeping everything nice and cool and happy - a good thing!

if you do not have a hose connected to the ports (either a manual or no 'aftercooler')
the short plug will block the drain area and the hose port so the radiator will not leak through either - a good thing!
the long plug will not block the hose port and you will rapidly lose fluid through this large opening - a bad thing!

Finally driving my car again and all is good!

[psmiddy]

Hoping you are still here 3 years later --

I met some strong resistance at the final ¼ “ and was not able to fully insert the plug housing.

What did you do to get the plug in the last 1/4 inch? I'm trying to install a greased long plug on passenger side, but seeing same resistance as you. I was thinking of gently tapping w a rubber mallet, but didn't want to inadvertently break something. How did you solve?