In the garage the other day and thought I'd check the various fluids. Noticed that the colour of the coolant looked rather orange. Became concerned that there may be issues with the coolant system. Took the decision to drain, fully flush out, clean up, check radiator and refill with new coolant.
The approach being to do this in two phases:
- Drain, fully flush out, clean up and refill with new coolant.
- Run for a couple of months and then drain, fully flush out, cleanup, replace all hoses/clips and refill with new coolant.
- Wait until engine has cooled.
- Do not allow antifreeze to come in contact with skin or painted surfaces.
- Take spent coolant to refuse site.
Draining
Here is the process that was used to drain the system.
- Set heating control to hot.
- Remove expansion tank filler cap.
- Position a container under the radiator.
- Disconnect radiator bottom hose and allow coolant to drain.
- When expansion tank has emptied remove thermostat housing plug to assist drainage.
- Similarly when coolant is below top of radiator, remove radiator plug.
- Remove air bleed hose connection from radiator.
- Remove the coolant drain plug from the left hand side of the cylinder block.
Flushing Radiator
Here is the process that was used to flush the radiator.
- Disconnect the radiator top hose.
- Insert garden hose into radiator top inlet.
- Continue flushing through until clear water emerges.
- Insert hose in bottom outlet and reverse flush the radiator.
Flushing Cylinder Block
Here is the process that was used to flush the cylinder block.
- Remove thermostat.
- With radiator top/bottom hoses still disconnected.
- Insert garden hose into radiator bottom hose.
- Direct clean flow of water until clean water emerges from radiator top hose.
- Refit thermostat.
Coolant Filling
Here is the process that was used to filling back again with coolant.
- Refit radiator top/bottom hoses.
- Refit engine block plug.
- Fill through expansion tank until radiator is full with level in expansion tank same as radiator.
- Fit plug back into radiator.
- Add further 1 litre of coolant into expansion tank and allow to settle.
- Refit expansion tank cap and thermostat housing plug.
- Run engine idle speed for 5 minutes.
- Switch off engine. allow to cool.
- Check level and top up if necessary.
Detailed notes
Here are some notes and images taken during the process.
Image taken from underneath engine bay. Highlighted is the hose clip for the bottom hose.
The bottom hose clip was more easily undone from beneath with a 7mm spanner. The hose itself then removed by leaning over into the engine bay from above. A builders mixing tray worked well for collecting all the coolant.
Coolant draining into builders mixing tray.
The plastic thermostat cap was removed with a 21mm spanner. The seal was disguarded.
Thermostat housing with plastic cap, securing bolts and hose clips.
The radiator cap was then removed using a 10mm allen key.
Radiator bleed value hose clip.
Radiator bleed value
Once the coolant had stopped draining out, it was pumped into a 5L container.
The amount of coolant drained at this point almost filled the container. The drain plug on the cylinder block was then removed. A little tricky to access - a short 13mm ratchet spanner worked well.
Cylinder block drain plug.
Once the cylinder block drain plug was removed, around a further 5L of coolant was drained and pumped into a second 5L container.
The thermostat elbow was removed in preparation for flushing out.
Thermostat elbow with thermostat present.
Thermostat block. Actually looking quite clean.
During the clean up process, the expansion tank was completely removed. This involved removing the plastic wing top cover plate to get access to remove all of the 3 nuts. One of the bolts did sheer so as such all three nuts and bolts will be replaced subsequently with new genuine parts - copper greased. In the meantime, replaced the sheered bolt with an M6 nut/bolt and washers.
Gave the expansion tank a good wash out. However, not really satisfied at this point that all the "sludge" was removed. Using an insepction lamp to examine, it seems to stick to the inside walls but yet not in a greasy way. Need to think how best to clean up more thoroughly. One for round two of the coolant cleanup.
Also, the undercarriage was given a good spray down with the hose to ensure no coolant left on the chassis, etc...
Also, the undercarriage was given a good spray down with the hose to ensure no coolant left on the chassis, etc...
Note that the plastic thermostat cap was replaced with a brass one along with a new seal - BR3485B (ERR4686B). A new copper washer (AFU1882L) was also used when refitting the cylinder block drain plug.
New coolant in the expansion tank. Looking more healthy at this stage.
Went for a short drive with the heater on maximum. The temperature gauge in the middle all the way. After the drive, the coolant was at expected levels also.
- 7mm spanner for bottom radiator hose worm drive hose clips.
- 10mm spanner.
- 13mm spanner for engine block.
- 21mm spanner for the therostat housing cap.
- 10mm allen key for the radiator cap.
- Torque wrench - 25Nm for theromstat housing bolts.
- Both flat and pozi drive screwdrivers.
- Penetrating fluid and 3:1 oil spray.
- Builders mixing tray.
- Funnel for filling coolant back into expansion tank.
- Oil pump.
- Containers for taking old coolant to the recycle center.
- Hose pipe for flushing and cleaning off under carriage.
- Bundles of rags.
An ethylene glycol based anti-freeze (no methanol) with non-phosphate corrosion inhibitors for use in aluminium engines. One part anti-freeze to one part water was used. The total amount of coolant used was around 11 litres - as measured from containers. The manual suggests that 11.5 litres of coolant is required.
Stage 2
This next stage is to replace all the rubber hoses and hose clips. Will do this in a couple of months. Here are some notes to help remind me of the parts need to order. Must credit lrworkshop.com for the images below.
Expansion tank hoses
17 - 1xPCH117840 - Hose-bleed pipe assembly to expansion tank
11 - 3xCN100208 - Clip-hose
Radiator hoses
10 - 1xERR4686B - Thermostat housing bung plug
11 - 1xERR4685 - O ring
Radiator houses
1 - 1xESR2298 - Top Radiator Hose
2 - 2xCN100508L - Clip-Hose, 50mm, less spring assist 3 - 1xESR3121/PCH119060 - Bottom Radiator Hose
4 - 2xCN100308L - Clip-hose
4 - 2xSTC7430 - Clip-Hose, 30mm
5 - 2xCN100508L - Clip-Hose, 50mm, less spring assist
6 - 2xESR2662 - Clip-Hose
Thermostat Housing
2 - 1xERR3291 - Thermostat
3 - 1xERR4686B - Bung
4 - 1xERR4685 - Seal
Cylinder block
4 - 1xERC9410 - Plug-Drain
5 - 1xAFU1882L - Washer-sump assembly drain plug
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