ENGINE 34 H. COOLANT REPLACEMENT 1. Allow the engine to cool up to ambient temperature 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 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 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 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.
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