General procedures
WARNING: To avoid scalding yourself from hot coolant or steam, take extra care when removing the coolant expansion tank seal when the cooling system is warm. Allow the engine to cool, then wrap a thick cloth around the expansion tank cap and slowly unscrew it until pressure build-up begins. Step back while depressurizing the cooling system. After making sure that the pressure is completely relieved, and without removing the cloth, turn and remove the sealed cap of the coolant expansion tank. Failure to follow these instructions may result in injury.
Caveats:
- To prevent corrosion and engine damage from freezing coolant, fill the engine cooling system with the correct grade of antifreeze at the correct concentration. Failure to do so may result in vehicle damage.
- Coolant that comes into contact with the paintwork can damage it. If you spill coolant, remove it immediately and flush the area with water.
1. Set heater controls to maximum heat (NOT).
2. Remove the hood.
For more information, see chapter: Bonnet (501-02 Front body panels, Removal and installation).
3.
WARNING: Do not remove the coolant expansion tank cap while the system is hot, as steam or coolant escaping from the cap could cause serious injury such as scalding.
Remove the filler cap of the coolant expansion tank.
4. Loosen the air bleed screw from the cooling system.
5.
WARNING: Do not work on or under a vehicle supported only by a jack. Always place secure supports under the vehicle.
Raise the car and place it on stands.
6.
WARNING: Eye protection required.
Install a container to collect the coolant.
7. Disconnect the 2 coolant pipes of the fuel cooler heat exchanger. Drain the coolant.
8. Disconnect the coolant hose from the engine oil cooler.
- Release the clamp.
- Drain the coolant.
9. Connect the coolant hose to the engine oil cooler. Install the clamp.
10. Connect the 2 fuel cooler heat exchanger coolant pipes. Remove container.
11. Tighten the air release screw from the cooling system.
12.
CAUTION: To prevent corrosion and engine damage from freezing coolant, fill the engine cooling system with the correct grade of antifreeze at the correct concentration. Failure to do so may result in vehicle damage.
Prepare a sufficient amount of coolant of the required concentration and pour it into a container.
13. Install the vacuum filling adapter of the cooling system on the expansion tank.
14. Install the vacuum filling gauge on the cooling system charging adapter.
15. Install the venturi assembly on the gauge of the vacuum filler.
16.
NOTE: Make sure both valves on the meter are in the closed position.
Connect the regulated compressed air supply line to the venturi assembly.
17.
NOTE: Make sure there is no air in the hose.
Place the coolant pickup tube in a container of clean coolant.
18. Place an air evacuation hose into the container.
19.
NOTE: Make sure the coolant supply valve on the vacuum filler gauge is in the closed position.
NOTE: The vacuum tool requires an air pressure of 6 to 8 bar to charge the coolant properly.
NOTE: Small diameter or long air lines may restrict airflow to vacuum coolant charging tool.
Open the air supply valve.
20. Open the coolant supply valve for 2 seconds to fill the coolant supply hose.
21. Gradually apply air pressure until the pointer on the vacuum filler gauge reaches the green segment.
22. Close the air supply valve and disconnect the pneumatic line.
23. Wait 1 minute to make sure the vacuum is maintained.
24. Open the coolant supply valve to prime the system with coolant.
25. When the expansion tank is full and the flow of coolant stops, close the coolant supply valve.
26. Remove the vacuum filling adapter and measuring device from the expansion tank.
27. Establish a cover of a jellied mouth of a broad tank of system of cooling.
28. Install the hood.
For more information, see chapter: Bonnet (501-02 Front body panels, Removal and installation).
29.
Caveats:
- Make sure the coolant level stays above the low level mark "COLD FILL RANGE" (REFILL RANGE FOR COLD CONDITION).
- Observe the readings of the engine temperature gauge. If the engine starts to overheat, shut it down immediately and let it cool down. Failure to do so may result in vehicle damage.
Start the engine and let it run.
- Maintain the engine speed at 3000 rpm for one minute.
- Let the engine run at idle for 5 minutes.
- Maintain the engine speed at 3000 rpm for one minute.
- Let the engine run until it reaches normal operating temperature.
30. Turn off the engine and let it cool down.
31.
WARNING: Do not remove the coolant expansion tank cap while the system is hot, as steam or coolant escaping from the cap could cause serious injury such as scalding.
Check coolant level, top up if necessary.
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