Industrial 1.6L Engine Cooling 2-9
2. Check the engine drain plug in order to ensure that the
drain plug is closed.
3. Place a large funnel in the radiator fill hole.
4. Fill the system with ethylene glycol based coolant to the
radiator. Do not pre–mix the coolant and water. Fill the
remainder of the radiator with clean drinkable water in
order to equal a 52/48 mix. Refer to Engine Cooling
System Specifications for the cooling system capacity.
The filling may be slowed due to the thermostat being
closed.
5. Fill the cooling system to 13 mm (1/2 in) below the fill
line.
6. Start the engine and allow the cooling system to warm
up. When the thermostat opens, the coolant level may
drop. If the level drops, add coolant until the level is up to
the top.
7. Replace the radiator cap.
8. Check the coolant level in the radiator surge tank, if
equipped. Add coolant as needed.
Flushing
Notice: If the engine is damaged internally and a new engine
assembly is installed, make sure all foreign material is
completely flushed out of the cooling system. The oil cooler
system should also be flushed out. Failure to rid the oil or
cooling system of debris can result in damage to the replace-
ment engine.
Important: Remove the thermostat before you flush the
cooling system.
Various methods and equipment can be used in order to
flush the cooling system. If you use special equipment such
as a back flusher, follow the equipment manufacturer’s
instructions.
Cooling System Scale Removal
In order to remove hardened scale, a direct chemical action
is necessary. Add a flushing compound in a dissolved
solution at the specified rate of 30 grams per liter (4 oz. per
gallon) of radiator capacity to the coolant water. Do this while
the water is running. Operate the engine for 15 minutes.
Then, drain and flush the system with clean water.
There are various types of flushing compounds available
commercially. Obtain the compounds from a reliable source.
Most compounds attack metals and should not remain in the
engine block for more than a few minutes. Use a neutralizer
in the cooling system immediately after you use a descaling
solvent.
Use a stronger solution for extremely hard, stubborn coat-
ings, such as lime scale. The corrosive action of a stronger
solution affects the thin metals of the radiator, which reduces
the operating life of the radiator. A complete flush and rinse of
the radiator is mandatory and must be accomplished skillfully.
Drain the entire system after the solvent and neutralizer are
used and the cooling system is flushed. Fill the system with a
48/52 mixture of distilled water and an ethylene glycol–
based coolant. Check for coolant leaks in the radiator, the
hose and the engine.
Repair Instructions
Draining and Filling Cooling System
Draining Procedure
Caution: The radiator cap should be removed from
a cool engine only. If the radiator cap is removed
from a hot cooling system, serious personal injury
may result.
Caution: As long as there is pressure in the
cooling system, the temperature can be consider-
ably higher than the boiling temperature of the
solution in the radiator, without causing the
solution to boil. Removal of the radiator cap while
the engine is hot and the pressure is high will
cause the solution to boil instantaneously and
possibly with explosive force, spewing the solu-
tion over the engine, body, and person removing
the cap. Under some conditions, the engine
coolant is combustible.
Use the following procedure in order to drain the
cooling system:
1. Place a drain pan under the radiator drain cock.
2. Install a tube on the drain cock.
3. Place the end of the tube in the drain pan.
4. Ensure the cooling system is cool. Remove the
radiator cap.
5. Open the drain cock completely.
6. Allow the cooling system to drain until the flow
stops.
7. Place a drain pan under the engine.
8. Remove the drain plug from the engine block.
9. Allow the engine block to drain until the flow
stops. There may be some more drainage from
the radiator at this time.
10. Replace the engine block drain plug.
11. Close the radiator drain cock.
Refilling Procedure
NOTICE: When refilling the engine cooling system,
ensure that the level is kept approximately 13 mm (1/2
in) below the fill line. This will help vent an air lock
from occuring in the system.
Monitor the engine closely on initial start up to make
sure the thermostat opens properly, allowing coolant to
recirculate. If the thermostat does not open, an air
lock may be present. In this instance it will be
necessary to install a bleed valve in a high point in the
system. Run the engine with the bleed valve installed
and open. Continue running until all air is purged from
the system and coolant is coming out of the bleed
valve.
Use the following procedure to refill the cooling
system:
1. Check the radiator drain cock to ensure that it is
closed.
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