1.5L REVOTORQ ENGINE 48 4. Initial coolant filling through pressure cap opening. Opening EGR hose and top hose of heater core. Filling coolant through pressure cap opening till coolant is visible in the EGR hose. Refit EGR hose. Keep filling coolant till coolant is visible in the heater hose. Refit the heater hose. Fill the no loss tank till the max level. 5. Start the engine and maintain engine 3000 rpm. Close the pressure cap & start the engine in idle condition for a few seconds. Rev up & maintain engine speed at 3000±100 rpm. Radiator fan switch ‘ON’ for the first time once coolant temperature reaches the fan trigger threshold. Continue the de-aeration process until completion of two heat cool cycles of radiator fan (i.e. Radiator fan turns ‘ON’ & ‘OFF’ for two times). Allow engine to cool down until coolant temperature reaches ambient temperature. 6. Fill coolant after vehicle cool down. After cool down, observe drop in coolant level in no loss tank & if required fill coolant until max mark. Also open pressure cap & fill coolant till the neck is full if required. De-aeration process is now complete. 7. Step to be follow during de-aeration process with coolant quantities. Sr. No. Stage Action Coolant Qty. (ml) 1 Initial filling Fill the coolant through pressure cap opening 3700 2 Cold fill – Engine off Coolant filled until max level of no loss tank 700 3 Pressure cap closed. Engine started & maintained at 3000±100 rpm with AC OFF. 4 2 Heat –Cool cycles done (i.e. Radiator fan turns ‘ON’ & ‘OFF’ for two times). 5 Engine OFF. Leave engine to cool down (preferably to ambient temperatures). 6 2nd filling Fill the coolant till neck of pressure cap 200 Fill the coolant till max level 400 Total Coolant filled 5000 iii. Wiring Harness Clip Removal NOTE Use clip removal tool to remove clips, pin where as necessary to avoid the damage.
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