Table of contents: Radiator cleaning ↓ Replacing coolant hoses ↓ Draining the coolant ↓ Filling the cooling system ↓
The hoses on the radiator and engine should be tightly fitted, as should the thin hoses going to the heater or to the intake pipe and starting automation.
Check for cracks in the hoses. Press on the hoses to check for hardened areas, if any, replace them
Check that the hoses are not pushed too deeply into the fittings.
Check the tightening of the clamp bolts.
Rusty clamps may 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 hand-held air pump and a pressure gauge.
This device is placed on the opening of the expansion tank and creates a pressure of 1 bar.
If the pressure does not drop within 1-2 minutes, the cooling system is sealed.
Radiator cleaning
Before and after the warm season, it is necessary to clean the radiator fins from insects that have gotten there, since their presence worsens heat exchange. On a four-cylinder engine, sow the radiator grille, 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 time has elapsed, rinse the radiator from the rear with water. Do not allow too much pressure to pass through the radiator fins. A hard brush or a sharp tool may damage the radiator. Rinse the radiator from the inside with water from a hose through the fan holes. On a five-cylinder engine, lift the rubber plugs on the right and left of the radiator trim and rinse the radiator through the holes under the plugs.
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 the hose clamps, disconnect the hoses.
Loosen tightly seated ends of hoses by inserting a screwdriver between the hose and the nipple and gently prying. Push new hoses onto the nipples far enough so that they cannot slip off.
Do not tighten the clamps with too much force, otherwise the threads may be stripped.
Attention. You can try to seal a hose with a crack using a special tape "Pan-pen-band" or "Hoseweld Bandage". Either one is glued to a clean and dry hose. If there is a large leak, you must first release the pressure in the cooling system, turn the cover of the distribution tank one turn, otherwise the bandage will not hold.
Draining the coolant
Allow the engine to cool down, otherwise there is a risk of liquid splashing out.
Open the expansion tank cap.
Place a tray 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 the liquid.
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 mounting 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 desired part of the radiator.
Caution. Particles of the corrosion protection agent contained in the additives in the coolant settle on the light alloy cooling system parts over time, forming a protective layer. If a large-surface part included in the cooling system is replaced, the corrosion protection agent remaining in the fluid may not be sufficient to protect the new part from corrosion. Therefore, when replacing the cylinder head, radiator, heat exchanger or the entire engine, it is necessary to completely replace the coolant.
Filling the cooling system
Add coolant until the expansion tank is filled to the brim.
On a four-cylinder engine, unscrew the large thermal switch in the hose connection on the left side of the cylinder head. Screw the thermal switch back in when coolant starts to leak out at this point.
On a six-cylinder engine, unscrew the air bleed plug located on the main cooling system line.
Tighten the tank cap.
Start the engine and let it run until the electric radiator fan comes on.
Turn off the engine and add coolant. When the engine is warm, the coolant level should be approximately 2 cm above the mark on the expansion tank.