Warning | Risk of injury. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | |
Warning | Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant. | Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. | |
Warning | Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | |
Flush without a cleaner | |||
1 | Start engine and warm up to operating temperature. | Coolant temperature approx. 80 °C. | |
2 | Switch off engine and allow to cool for approx. 30 min. | So that any oil that may be present in coolant expansion reservoir can settle. | |
3 | Check whether there is oil in coolant expansion reservoir. | If oil is located in coolant expansion reservoir | |
| |||
Suction off coolant/oil mixture from coolant expansion reservoir and dispose of in an environmentally compatible manner. | |||
4 | Drain off coolant completely. | ||
5 | Remove the coolant expansion reservoir. | See information from body manufacturer. | |
6 | Disconnect feed and return hoses of heating. | If installed. | |
See information from body manufacturer. | |||
7 | Flush heating system with fresh water. | If installed. | |
See information from body manufacturer. | |||
8 | Reconnect feed and return hoses of heating. | If installed. | |
See information from body manufacturer. | |||
9 | Disconnect coolant hoses at interfaces between engine and cooler. | ||
10 | Flush engine and cooler with fresh water. | If possible use hot or warm water. Dispose of rinsing water in an environmentally friendly way. | |
11 | Attach coolant hoses to interfaces between engine and cooler. | ||
12 | Release coolant hose at retarder return fitting and slide onto retarder pipe. | Only for secondary coolant-retarder | |
13 | Release retarder coolant feed and return hoses at clamps at engine. | Only for secondary coolant-retarder | |
14 | Flush retarder coolant pipes with fresh water. | Only for secondary coolant-retarder | |
If possible use hot or warm water. Dispose of rinsing water in an environmentally friendly way. | |||
15 | Attach retarder coolant hoses. | Only for secondary coolant-retarder | |
Screw clamps are used to clean and flush. | |||
Pliers | |||
Remove oil | |||
16 | Install the opened coolant thermostat. | ||
| Open coolant thermostat for oil removal | ||
Both cooling circuits are flushed via installation of opened coolant thermostat. | |||
17 | Mix a 3% cleaning solution consisting of a mildly alkaline cleaner and fresh water. | | |
Mixing ratio: 30 ml cleaner to 1 l fresh water. Dispose of cleaning solution in an environmentally acceptable manner. | |||
Cleaner for engine and cooling system for oil drag-in, 10 l | |||
18 | Flush coolant expansion reservoir with 3% cleaning solution. | ||
19 | Install coolant expansion reservoir. | See information from body manufacturer. | |
20 | Fill engine cooling system with 3% cleaning solution. | ||
21 | Set heating to max. heating output. | If installed. | |
See information from body manufacturer. | |||
22 | Switch on ignition and select 4th brake stage of retarder. | Only for secondary coolant-retarder | |
See information from body manufacturer. | |||
23 | Start engine, warm up to approx. 60 °C coolant temperature and maintain at this coolant temperature for approx. 5 min. | | |
If necessary, cover radiator to achieve coolant temperature of 60 °C. | |||
24 | Switch off engine and allow to cool to approx. 50 °C coolant temperature. | ||
25 | Switch off retarder. | Only for secondary coolant-retarder | |
26 | Fully drain cleaning solution out of engine cooling system. | | |
Dispose of cleaning solution in an environmentally acceptable manner. | |||
Flush after deoiling | |||
27 | Flush engine, cooler, if necessary heating and if necessary coolant pipes of retarder with fresh water. | Perform operation steps 6 to 15 to flush with fresh water. | |
28 | Fill and flush engine cooling system at least twice with fresh water. | | |
| |||
Allow engine to run for approx. 5 min during each flushing process. | |||
29 | Check flushing water of last flushing process for oil drag-in. | If oil is still present in flushing water, | |
| |||
Repeat deoiling and perform work from operation step 20. | |||
30 | Check flushing water of last flushing process for acid content using a test strip. | Test strips show the pH value. | |
If flushing water of last flushing process is not pH neutral | |||
| |||
Repeat engine cooling system flushing with fresh water once. | |||
| |||
31 | Replace an opened coolant thermostat by the previously removed coolant thermostat. | ||
Clean coolant thermostat before installation. | |||
32 | Fill in coolant. |
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