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4 DLT ENGINE
SERVICE INSTRUCTION FOR ALUMINUM
RADIATORS
1. Introduction
This manual explains the procedure for servicing of
Aluminum Radiators with plastic tanks. The following
aspects are covered :–
Leakage spot detection Sealing Techniques
Confirmation of proper sealing
2. Procedure for Servicing
2.1 Removal of Radiator from Vehicle
l Allow the coolant in the radiator to reach to the
room temperature.
l Drain the coolant from radiator completely.
l Take out the radiator from vehicle carefully to
avoid damage to any of it’s parts
CAUTION : Radiator core and plastic tanks are
susceptible to cracking due to impact and
deformation
2.2 Detection of Leakage Spot
Connect the inlet of the radiator to air supply at the
gauge pressure of 1.5 bar
Seal all other outlet points
Dip the radiator completely in a clean water tank
Tilt the radiator and shake it vigorously to let the air
bubbles trapped at the clinching area to escape
Observe carefully for one minute and locate the
source of air leakage on the radiator from the direction
of air bubbles that are coming out of radiator
If the Leakage spot is at radiator core then follow the
procedure given at . 2.3 to seal the leakage
Else if the Leakage spot is found at Tank or its
accessories then follow the procedure given at
2.4 to seal the leakage
CAUTION : Do not use the water tank that is used
for copper radiator
2.3 Sealing the Leakage at Radiator Core
Different procedure of sealing shall be followed for
MINOR and MAJOR leaks in the radiator core.
MINOR LEAKS : Leak spots which are very minute
are to be sealed in following manner
l Install the radiator on vehicle as explained .
3 (Radiator Installation)
l Pour the contents of ALUMASEAL in the
radiator.
l Fill proper quantity of coolant liquid.
l Run the engine in idling speed for 20 minutes
MAJOR LEAKS : Procedure of sealing major leaks
in the radiator is as follows:
l Wash the core with clean water and brush to
remove dirt, dust etc.
l To remove the greasy spot on the core, apply
thinner with cotton swab and take off the grease.
l Dry the core using a dryer (Do not use heating
source)
l Mix adequate quantity of ARALDITE RESIN
(Araldite rapid may be used in place of Araldite
standard for faster drying & curing of seal) and
HARDENER in the ratio of 1:1 and stir it
thoroughly
l Apply the mixture immediately at the leakage
spot with the applicator.
l Allow the mixture to dry and harden under the
shade at room temperature for 10-12 hour.
l Silver color paint may be used for touching up
the araldite spots and impart the aluminum type
appearance.
CAUTION : -
l Do not damage the fins during process.
l As the Araldite is inflammable do not dry it by
using any heating source.
l Proper cleaning of leakage area is must for
proper setting of Araldite or else it will come off.
2.4 Servicing of Tank and its accessories
l If the source of leakage is tank, then replace
the tank.
l Take out the member support using correct size
spanner Remove the tabs of the header plate
using screw driver and monkey plier.
l After making all clinching projections up, take
out the tank from its seat in header plate.
l In case it takes more effort, pat the tank with
rubber or plastic hammer lightly.
l Take of the tank packing.