General procedures
WARNING: To avoid being scalded by hot coolant or steam, use extreme caution when removing the coolant expansion tank pressure cap when the cooling system is hot. Allow the engine to cool, then wrap a thick cloth around the coolant expansion tank cap and slowly loosen it until the pressure release process begins. Step back while the cooling system releases pressure. After ensuring that all pressure has been released, and without removing the cloth, twist and remove the coolant expansion tank pressure cap. Failure to follow these instructions could result in personal injury.
Warnings:
- To prevent corrosion and engine damage from freezing coolant, the engine cooling system must be filled with the correct grade of antifreeze in the correct concentration. Failure to do so may result in damage to the vehicle.
- Coolant may damage paintwork if it comes into contact with it. If you spill coolant, clean it up immediately and rinse the area with water.
1. Set the heater controls to maximum heat (HOT).
2. Remove the hood.
For more information, see the chapter: Hood (501-02 Front body panels, Removal and installation).
3.
WARNING: Never remove the coolant expansion tank cap when the system is hot, as steam or coolant escaping from the cap could cause serious injury such as scalding.
Remove the coolant expansion tank filler cap.
4. Loosen the cooling system air bleed screw.
5.
WARNING: Do not work on or under a vehicle supported solely by a jack. Always support the vehicle securely.
Raise the vehicle and support it on jack stands.
6.
WARNING: Eye protection required.
Install a container to collect the coolant.
7. Disconnect the 2 fuel cooler heat exchanger coolant pipes. 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 coolant pipes of the fuel cooler heat exchanger. Remove the container.
11. Tighten the cooling system air bleed screw.
12.
CAUTION: To prevent corrosion and engine damage from freezing coolant, the engine cooling system must be filled with the correct grade of antifreeze at the correct concentration. Failure to do so may result in damage to the vehicle.
Prepare a sufficient amount of coolant of the required concentration and pour it into a container.
13. Install the cooling system vacuum filler adapter onto the expansion tank.
14. Install the vacuum filling device measuring device onto the cooling system filling adapter.
15. Install the venturi tube assembly onto the vacuum filling instrument measuring device.
16.
NOTE: Make sure both valves on the measuring device are in the closed position.
Connect the regulated compressed air supply line to the venturi assembly.
17.
NOTE: Make sure no air gets into the hose.
Place the coolant pickup tube in a container of clean coolant.
18. Place the air extraction hose into the container.
19.
NOTE: Make sure the coolant supply valve on the vacuum filler gauge is in the closed position.
NOTE: The coolant filling vacuum tool requires an air pressure of 6 to 8 bar to operate properly.
NOTE: Small diameter or long air lines may restrict air flow to the coolant filler vacuum 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 needle on the vacuum filling device gauge reaches the green segment.
22. Close the air supply valve and disconnect the pneumatic line.
23. Wait 1 minute to ensure the vacuum is held.
24. Open the coolant supply valve to fill the system with coolant.
25. When the expansion tank is full and the coolant flow stops, close the coolant supply valve.
26. Remove the vacuum filling adapter and measuring device from the expansion tank.
27. Install the filler cap of the expansion tank of the cooling system.
28. Install the hood.
For more information, see the chapter: Hood (501-02 Front body panels, Removal and installation).
29.
Warnings:
- Make sure the coolant level remains above the low level mark "COLD FILL RANGE" (REFUELING RANGE FOR THE COLD STATE).
- Monitor the engine temperature gauge. If the engine starts to overheat, turn it off immediately and allow it to cool. Failure to do so may result in damage to the vehicle.
Start the engine and let it run.
- Maintain the crankshaft speed at 3000 rpm for one minute.
- Let the engine idle for 5 minutes.
- Maintain the crankshaft speed at 3000 rpm for one minute.
- Allow the engine to run until normal operating temperature is reached.
30. Turn off the engine and let it cool.
31.
WARNING: Never remove the coolant expansion tank cap when the system is hot, as steam or coolant escaping from the cap could cause serious injury such as scalding.
Check the coolant level and top up if necessary.
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