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ENGINE
48
viii.
Coolant Replacement :
1. Allow the engine to cool up to ambient
temperature if it is hot.
2. Open the pressure cap.
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
housing, remove one of hose either bypass
pipe hose on thermostat housing or hose (Oil
cooler return pipe) on thermostat housing.
The coolant in engine 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
Ensure 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.
The Complete cooling system including oil
cooler will be drained.
Coolant Re-Filling Procedure :
1. Reconnect all the hoses and thermostat and
secure 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 thermostat)
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.