Installation Manual

3
• Engines having an “inlet side” thermostat and a good block drain (e.g., DD15) do not require removal
of the thermostat. With the block drain open, air blown toward the engine through the top radiator
hose will purge the residual coolant in the block.
• Completely empty the overflow bottle if the vehicle is equipped with one. If the system has a
pressurized expansion tank, blow air into it to make sure it is empty.
2. Purge the System:
• Close all drain valves, plugs, and vents, and reconnect circuits. If the engine is equipped with a
coolant filter (heavy duty systems), replace the filter with one that does not introduce coolant
additives.
• Fill the system with Prep Fluid to flush parts of the cooling system suspected of harboring residual
coolant or water. DO NOT use water. Vent as needed to ensure complete fill.
• Replace the pressure cap and run the engine with the heater on, at full hot, for 10 minutes after
reaching operating temperature (thermostat open).
• Repeat the sequence given in step 1 to drain out the used Prep Fluid.
3. Refill the System:
• Close all drain valves, plugs and vents, and reconnect all circuits.
• Fill system completely with the appropriate EWC, and start engine. Add coolant as needed to keep
system full. If system is equipped with a vented overflow bottle, leave it empty for now.
• Replace the pressure cap and run engine with the heater on, at full hot, for 10 minutes after reaching
operating temperature (thermostat open). Shut the engine off and allow the system to cool.
4. Test the Coolant:
• Draw a sample of well-circulated coolant from the radiator or pressurized overflow reservoir. Check
the water content using a refractometer or test strips as outlined in Appendix 1. The coolant being
tested must be at room temperature before testing. Caution – minimize exposure of the coolant to
air during testing.
• If the above procedure has been rigorously followed, the water content of the coolant should be
within specification (below 3 percent). If the water content exceeds 3%, run the system again to
operating temperature, and allow sufficient time for the thermostat to open and fluid to circulate
through the radiator. Repeat sampling and water content test. If the water content still exceeds the
limit, see remediation procedure under Test Strips in Appendix 1.
• If the water content is 3% or less, the equipment is ready for use. Ensure the overflow bottle or
expansion tank is filled to the “cold” mark with EWC. Place Evans warning stickers in strategic
locations (radiator cap, radiator shroud, overflow bottle, expansion tank) to warn against adding
water or water-based coolant to the system.
• Upon cool-down and for a few days thereafter, small amounts of coolant addition may be necessary.
Whether the system has a pressurized expansion tank or an overflow bottle, the coolant level should
be at the cold line when the engine is cold.