Every 2 Years; Coolant Renewal; Cooling System Draining; Cooling System Flushing - Opel Kadett Owner's Manual

Maintenance procedures

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Every 2 Years

32 Coolant renewal

Cooling system draining

Warning: Wait until the engine is
cold before starting this
procedure. Do not allow
antifreeze to come in contact
with your skin or painted surfaces of the
vehicle. Rinse off spills immediately with
plenty of water. Never leave antifreeze
lying around in an open container or in a
puddle in the driveway or on the garage
floor. Children and pets are attracted by its
sweet smell. Antifreeze is fatal if ingested.
1 To drain the cooling system, remove the
expansion tank filler cap. Turn the cap anti-
clockwise until it reaches the first stop. Wait
until any pressure remaining in the system is
released then push the cap down, turn it anti-
clockwise to the second stop and lift off.
2 Position a suitable container beneath the
radiator bottom hose union.
3 Slacken the hose clip and ease the hose
from the radiator stub. If the hose joint has not
been disturbed for some time, it will be
necessary to gently manipulate the hose to
break the joint. Do not use excessive force, or
the radiator stub could be damaged. Allow the
coolant to drain into the container.
4 As no cylinder block drain plug is fitted and
the radiator bottom hose union may be
situated halfway up the radiator, this may not
fully drain the cooling system.
5 If the coolant has been drained for a reason
other than renewal, then provided it is clean
and less than two years old, it can be re-used.
6 Reconnect the hose and securely tighten its
retaining clip on completion of draining.

Cooling system flushing

7 If coolant renewal has been neglected, or if
the antifreeze mixture has become diluted,
then in time, the cooling system may gradually
lose efficiency, as the coolant passages
become restricted due to rust, scale deposits,
and other sediment.
8 The cooling system efficiency can be
restored by flushing the system clean.
9 The radiator should
independently of the engine to avoid
unnecessary contamination.
Radiator flushing
10 To flush the radiator, drain the cooling
system then proceed as follows.
11 Slacken the retaining clips and disconnect
the top and bottom hoses from the radiator.
12 Insert a garden hose into the radiator top
inlet. Direct a flow of clean water through the
radiator, and continue flushing until clean
water emerges from the radiator bottom outlet.
13 If after a reasonable period, the water still
does not run clear, the radiator can be flushed
32.19a On 1.2 litre models, bleed the
cooling system through the cylinder head
with a good proprietary cleaning agent. It is
important that the manufacturers instructions
are followed carefully. If the contamination is
particularly bad, insert the hose in the radiator
bottom outlet, and flush the radiator in reverse.
Engine flushing
14 To flush
thermostat as described in Chapter 3, then
temporarily refit the thermostat cover.
15 With the
disconnected from the radiator, insert a
garden hose into the radiator top hose. Direct
a clean flow of water through the engine, and
continue flushing until clean water emerges
from the radiator bottom hose.
16 On completion of flushing, refit the
thermostat and reconnect the hoses with
reference to Chapter 3.
Cooling system filling
17 Before attempting to fill the cooling system,
make sure that all hoses and clips are in good
condition, and that the clips are tight. Note that
an antifreeze mixture must be used all year
round, to prevent corrosion of the engine
components (see following sub-Section). Also
check that the radiator and cylinder block drain
plugs are in place and tight.
18 Remove the expansion tank filler cap.
19 On 1.2 litre models, disconnect the heater
hose from the cylinder head, on 1.3, 1.4 and
later 1.6 litre engines models, disconnect the
wire and unscrew the coolant temperature
sender from the inlet manifold. On early 1.6,
and all 1.8 and 2.0 litre models, unscrew the
be flushed
bleed screw which is situated in the
thermostat housing cover (where no bleed
screw is fitted, unscrew the temperature
sender unit) (see illustrations).
20 Fill the system by slowly pouring the
coolant into the expansion tank to prevent
airlocks from forming.
21 If the coolant is being renewed, begin by
pouring in a couple of litres of water, followed
by the correct quantity of antifreeze, then top-
up with more water.
22 When coolant free of air bubbles emerges
from the orifice, reconnect the heater hose (1.2
litre models) or refit the coolant temperature
heater hose outlet
the engine, remove the
top and bottom hoses
32.19b On 1.3 litre models, unscrew
temperature gauge sender unit from the
manifold to bleed the cooling system
sender/bleed screw (as applicable) and tighten
it securely (all other models).
23 Top-up the coolant level to the "KALT" (or
"COLD") mark on the expansion tank, then
refit the expansion tank cap.
24 Start the engine and run it until it reaches
normal operating temperature, then stop the
engine and allow it to cool.
25 Check for leaks, particularly around
disturbed components. Check the coolant
level in the expansion tank, and top-up if
necessary. Note that the system must be cold
before an accurate level is indicated in the
expansion tank. If the expansion tank cap is
removed while the engine is still warm, cover
the cap with a thick cloth, and unscrew the
cap slowly to gradually relieve the system
pressure (a hissing sound will normally be
heard). Wait until any pressure remaining in
the system is released, then continue to turn
the cap until it can be removed.
Antifreeze mixture
26 The antifreeze should always be renewed
at the specified intervals. This is necessary
not only to maintain the antifreeze properties,
but also to prevent corrosion which would
otherwise occur as the corrosion inhibitors
become progressively less effective.
27 Always use an ethylene-glycol based
antifreeze which is suitable for use in mixed
metal cooling systems. The quantity of
antifreeze and levels of protection are
indicated in the Specifications.
28 Before adding antifreeze the cooling
system should be completely drained,
preferably flushed, and all hoses checked for
condition and security.
29 After filling with antifreeze, a label should
be attached to the expansion tank stating the
type and concentration of antifreeze used and
the date installed. Any subsequent topping up
should be made with the same type and
concentration of antifreeze.
30 Do not use engine antifreeze in the screen
washer system, as it will cause damage to the
vehicle paintwork. A proprietry screen should
be added to the washer system in the
recommended quantities.