Update: DIY
Comprehensive n Crazy Cooling System flush.
Need: While the coolant was changed on time, it was never flushed properly in 18 years. All the mechanics did was drain the coolant and fill in new one. Also when I was a kid, I remember seeing some mechanics at dealer workshops topping up the radiator with tap water. So it was decided, a thorough cleaning should be done. As such, there was no issue at all with the car, except some traces of dust floating in the expansion tank.
What I needed: - Ring Spanner 10-11mm
- Ring Spanner 12-13mm
- Long Nose Pliers
- Screw Driver
- Tub
- 1L Maruti Genuine Coolant Concentrate
- 30L distilled water, priced at Rs. 7.50 per bottle.
- Liqui Moly Radiator Flush
- 10L IPA(IsoPropyl Alchohol), given by my college's lab assistant
- Large drum(borrowed a 210L drum from my MASS)
Challenges & Precaution:
1. Nothing, other than finding a proper recycling and disposal centre. Everyone recommended putting it down the drain, but the anti freeze smells really fruity, and I didn't want any stray animals to taste it, as its poisonous. Lastly, got contact details of a certified waste recycling centre, and handed them over the flushed liquid.
2. Also, perform all these stunts only when the cooling system is cold, otherwise be prepared to receive a nice burning facial as soon as the radiator cap is removed.
3. Always have an eye on the temperature gauge for any spikes etc.
Process: Day 1: Time involved: 30 minutes
1. Remove the radiator drain plug and the radiator cap. Removing the radiator cap ensures faster draining. This drain plug according to Suzuki's Service manual is present only in F8D 800s(aka 5 Speed). For other 800s, it can be done by opening the lower radiator hose. Let coolant drain. Put back the drain plug once the coolant has come out. Drain and flush the coolant in the expansion tank too. Pulling the expansion tank straight up releases it from its hook.
2. Pour 2L distilled water plus radiator flush into the radiator, and rest in the expansion tank. Drive the car for 30kms(1 day)
Day 2: Time involved=3 hours
3. Drain the radiator. At this point, I removed the radiator from the car. Disconnected the upper and lower radiator hoses, and unscrewed the two 10mm bolts which holds the upper radiator mount. Disconnect the pipe of the expansion tank, and pull the radiator straight up. Also remove the expansion tank and flush it with running water.
4. Took the radiator and soaked it up in IPA for 1 hour. The amount of dirt settled in the fins was unbelievable. The whole IPA turned mucky in no time.
After washing the radiator, took it to my bed and with the help of a safety pin and old metal comb, straightened most of the bent fins. I hate working in an uncomfortable way, so took it on my bed, and patiently straightened every single bent fin.
Day 3: Time involved=2 hours
5. Removed the thermostat by removing two 12mm nuts. Borrowed a high pressure washer and put its nozzle in the coolant intake side, and flushed everything nicely from the blocks. Surprisingly nothing much came out at that time. Again mounted back everything, added 2L distilled water plus flush and happily drove to work.
In the evening, again drained the contents after driving around 30kms for a day. At this time, from the coolant intake side, a lot of muck and scale type of things came out. I checked the debris, and it was proper muddy, and didn't find any rust particles.
Day 4 & 5:
I repeated the process of filling and draining thrice, but this time only with pure distilled water(no flush).
Day 6: After the last 2 flushes, no unwanted muck came out, and I was sure, the system is as clean as it can be. I hence drained out the radiator for the last time, and added 1.90L distilled water and 1L antifreeze, so that the ratio is close to the desired 1:2.
All this while, I made sure all the drained fluid was properly collected in the 210L drum.
Cost involved:
* 1L Maruti Genuine Coolant Concentrate=Rs. 285
* 30L distilled water, priced at Rs. 7.50 per bottle=Rs. 225
* Liqui Moly Radiator Flush=Rs. 145x2=Rs.290(Amazon Flash sale)
* Thermostat Gasket: Part No=17569M82001=Rs. 3.41
Total: Rs.803.41
Pics:
Items required
Visible: Upper radiator hose, upper radiator mounts and the expansion tank hose
Lower radiator hose
Drain Plug
Thermostat cap: Make sure the air bleed valve of the thermostat aligns with the arrow mark
Hook which holds the expansion tank in place, pull the tank upwards to release
Radiator flush: Used two of them
Maruti Genuine Coolant
Floating dirt in the tank, before flushing
Dirty radiator, before cleaning
After cleaning, assembling the radiator
Dirt which came out after the 4th flush. Two more were performed after this
Crystal Clear coolant, after the entire process
I am not much of a DIY person, so was pretty nervous in the beginning. Thanks to the moral support I got from BHPians like Saket77, Paragsachania and Captain Slow, I could complete the DIY without ruining any other thing. Also this awesome thread by BHPian a4anurag helped me to visualise the entire process:
http://www.team-bhp.com/forum/diy-do...ti-wagonr.html
If anything else you'd like to recommend, I am all ears.
Signing off with a picture of two cars, delivered on the very same day. Meeting after 17.5 years.
Thanks for reading!
Regards,
Shashi