Check for cracks in hoses. By pressing on the hoses, check for the presence of hardened places in them, if any, replace them
Check if the hoses are pushed too deep into the fittings.
Check tightening of clamp bolts.
Rusted clamps can suddenly burst while driving when the pressure in the system is high, so they should be replaced.
In the workshop, the tightness of the cooling system is checked using a special manual air pump and a pressure gauge.
This device is put on the opening of the expansion tank and a pressure of 1 bar is created.
If the pressure does not drop within 1-2 minutes, then the cooling system is tight.
Radiator cleaning
Before and after the warm season, it is necessary to clean the radiator plates from insects that have got there, since their presence impairs heat transfer. On a four-cylinder engine, sow the radiator grill; on a five-cylinder engine, remove the radiator lining from above.
Remove traces of dried insects with a protein-dissolving agent, for example "Summer Screen".
After the agent has expired, rinse the radiator from the back with water. Do not pass too much pressure through the radiator fins. A hard brush or sharp tool may damage the radiator. Rinse the inside of the radiator with water from a hose through the fan openings. On a five-cylinder engine, lift the rubber plugs on the right and left on the radiator grille and flush the radiator through the plug holes.
Replacing coolant hoses
When replacing hoses, pay attention to the shape of the bends of the original hoses and replace all clamps.
Drain the coolant, collecting it. Loosen hose clamps, disconnect hoses.
Loosen tight-fitting ends of the hoses with a screwdriver, pushing it between the hose and the nozzle and prying carefully. Slide the new hoses far enough over the fittings so that they cannot slip off.
Do not tighten the clamps with great force, otherwise the threads may be stripped.
Attention. You can try to seal a hose with a crack with a special tape "Rappe-band" or "Hoseweld Bandage". That went another is pasted on the cleared and dry hose. In case of a large leak, you must first relieve the pressure in the cooling system, turn the cap of the distribution tank one turn, otherwise the band will not hold.
Coolant drain
Allow the engine to cool down, otherwise there is a risk of fluid splashing out.
Open the cover of the expansion tank.
Place a drip pan under the engine to collect the coolant. On a four-cylinder engine, disconnect the thick radiator hose on the engine on the left in the direction of travel and the thin hose to the heater heat exchanger on the coolant pump housing and drain off the coolant.
On a five-cylinder engine, disconnect the hose on the left in the direction of travel between the thermostat housing and the coolant pipe. Loosen the coolant pipe bolt and pull off the hose.
If necessary, also remove the hose between the radiator and thermostat.
On a six-cylinder engine, unscrew the drain plug (2) in the right part of the radiator.
Attention. Particles of the anti-corrosion agent contained in the additives in the coolant are deposited over time on the parts of the cooling system made of light alloy, forming a protective layer. If a part with a large surface area included in the cooling system is replaced, the corrosion protection agent remaining in the fluid may not be sufficient to protect this new part from corrosion. Therefore, when replacing the cylinder head, radiator, heat exchanger or the entire engine, the coolant must be completely replaced.
Filling the cooling system
Pour in coolant until the expansion tank is filled to the brim.
On a four-cylinder engine, unscrew the additional large thermal switch in the hose connection on the left side of the cylinder head. Tighten the thermal switch again when coolant starts to flow out at this point.
On a six-cylinder engine, unscrew the air release plug located on the main cooling system pipe.
Screw on the tank lid.
Start the engine and let it run until the electric radiator fan turns on.
Stop the engine and add coolant. When the engine is warm, the fluid level should be approximately 2 cm above the mark on the expansion tank.
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