73 / 1575
ENGINE
34
H. COOLANT REPLACEMENT
1. Allow the engine to cool up to ambient tempera-
ture if it is hot.
2. Open the pressure cap (1).
3. Drain the recovery bottle.
4. Keep a suitable container below the radiator
drain plug to collect the coolant that will drain.
5. Loosen and remove the drain plug and drain
coolant.
6. Remove the filler hose and drain coolant in it.
7. Keep suitable container below thermostat hous-
ing, remove one of hose either bypass pipe hose
on thermostat housing or hose (Oil cooler return
pipe) on thermostat housing. The coolant in en-
gine block will get drain.
8. Flush the fresh water in system and radiator till it
found color less at drain position.
9. Refit the coolant cap and radiator drain plug after
the coolant gets drained property.
10. Refit hoses and hose clamp.
NOTE
Even after the coolant is completely drained from the
radiator drain plug there will be coolant present in
hoses. Wherever possible bend the hoses slightly to
allow the coolant to flow out.
COOLANT RE-FILLING PROCEDURE
1. Reconnect all the hoses and thermostat and se-
cure the hose clamps properly.
2. Refit the radiator drain plug.
3. Use a funnel to fill coolant.
4. Hold the funnel over coolant tank. Refill the
coolant in the system through funnel. The filling
rate should be 1.0 liter / min approx.
5. When coolant level comes up to coolant tank
max level, wait and allow air bubbles to escape
from the system for 5 to 10 min. Top up coolant
once the level drops.
6. Start the engine and run in stationary condition
at 2000 to 2200 rpm till thermostat opens and
continue to run for 5 mins. (The radiator fans
coming on is indication of opening the thermo-
stat)
7. Wait after stopping the engine to allow engine to
come at atmospheric temp. Top up coolant in
filler neck after stopping the engine.
8. Repeat the step 6 and 7 twice.
9. The coolant refilling is complete now.
10. Ensure that there are no leakage in the complete
cooling system.