Coolant Fill Procedure:

For best results, Bostig recommends filling and flushing the cooling system with plain water before filling with coolant mixture.  While this step is not an absolute necessity, it will help to clean out any sediment that may have settled in the engine while in storage and will allow your cooling system to work at maximum efficiency.

Before starting the van for the first time be sure to set up your SCT Flash/Log tool for datalogging.  By logging your first start we will be able to review the initial settings as well as analyze any problems that may appear with your initial start on the off chance that they should appear.  Instructions for setting up the SCT datalogger can be found here:

Fill the expansion tank with 50/50 coolant mix until it is full and all bubbling has stopped.  Gently squeezing the main coolant hoses will help to dislodge trapped bubbles and will facilitate filling the system quickly and completely.

Remove upper radiator grill at front of van to allow access to radiator bleed bolt.  Turn heater controls to maximum heat and set air discharge to floor vents. Turn blower to high.

Install datalogger and begin the data capture.  Allow datalog capture to continue for the duration of the first run.  Start engine and idle with expansion cap removed for 2-3 minutes.  Add coolant as necessary to keep tank topped up during this period.  Once the tank will take no more coolant reinstall the blue expansion tank cap. 

FROM THIS POINT ON DO NOT REMOVE THE EXPANSION TANK CAP UNLESS THE ENGINE IS COMPLETELY COOL.

Allow the engine to idle until normal operating temperature is reached.  Hot air should discharge from floor vents.  Coolant temperature gauge should maintain a stable reading in middle of range. The main coolant return hose from the thermostat housing should feel very warm to the touch.

Loosen radiator bleed screw and allow any trapped air to escape.  Stop engine and allow it to cool completely. Top off coolant as necessary.

If coolant level/overheat alarm indicator (LED at middle of temp gauge in dash) flashes at any time, additional coolant may be needed.  Be sure to keep an eye on the coolant level for the first few drive cycles and add coolant, bleed air as necessary.

Email complete initial run datalog to us for review.   FAILURE TO PROVIDE US WITH A DATALOG OF INITIAL START/RUN/DRIVING CYCLE OF THE VAN TO OBTAIN A “GO-AHEAD” ON YOUR LOG RESULTS CAN DAMAGE YOUR CONVERSION AND VOID YOUR WARRANTY AND RIGHT TO FUTURE SUPPORT.  This policy / scary warning is in effect to protect our installers and to stress the importance of following the datalogging procedure to protect your conversion.