3. Remove coolant from water pump, heater and cooling system hoses. Open the heater top hose & blow • pressurized air in the heater top hose thermostat side (block the heater inlet part towards heater coil with the help of plug). Repeat same operation in reverse direction • (heater inlet towards heater coil side air will be blown & thermostat side will be closed). Connect the heater top hose. Close the • drain plug. 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. • Diesel Engine Ph-2 (CAFÉ) 57
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