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.
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 can damage paintwork. If you spill coolant, clean it up immediately and rinse the area with water.
1. Set the heater controls to maximum heat (HOT).
2. Unscrew the expansion tank cap.
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.
3. Raise the vehicle and place it on supports.
WARNING: Do not work on or under a vehicle supported solely by a jack. Always support the vehicle securely.
4. Remove the engine guard. Refer to procedure: Engine Guard (501-02 Front Body Panels, Removal and Installation).
5. Remove the right front mudguard.
NOTE: Wheel shown removed for clarity.
6. Place a container to collect the liquid.
7. Connect the hose to the radiator drain cock.
8. Open the radiator drain cock.
9. Drain the coolant from the radiator.
10. Remove the drain plug.
11. Drain the coolant from the engine.
12. Close the radiator drain cock and remove the hose.
13. Screw in the drain plug. Tightening torque: 23 Nm
14. Prepare a sufficient amount of coolant of the required concentration.
15. Install the cooling system vacuum filler adapter onto the expansion tank.
16. Install the vacuum filling device measuring device onto the cooling system filling adapter.
17. Install the venturi tube assembly onto the vacuum filling instrument measuring device.
18. Connect the regulated compressed air supply line to the venturi tube assembly.
19. Place the coolant pickup tube in a container of clean coolant.
NOTE: Make sure no air gets into the hose.
20. Place the air extraction hose into the container.
21. Open the air supply valve.
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.
22. Open the coolant supply valve for 2 seconds to fill the coolant supply hose.
23. Gradually apply air pressure until the needle on the vacuum filling device gauge reaches the green segment.
24. Close the air supply valve.
25. Wait 1 minute to ensure the vacuum is held.
26. Disconnect the compressed air supply line.
27. Open the coolant supply valve to fill the system with coolant.
NOTE: When the coolant reaches the upper (MAX) mark on the expansion tank or the coolant stops flowing, close the coolant supply valve.
28. Remove the vacuum filler gauge and the cooling system filler adapter assembly.
29. Connect the exhaust hoses to the rear exhaust pipes.
30. Start the engine and let it run.
31. Install the coolant expansion tank cap.
32. Maintain the engine speed at 2000 rpm until warm air comes out of the heater.
33. Turn off the engine and allow it to cool.
34. If coolant gets on your car, wipe it off.
35. Check the coolant level and top up if necessary.
CAUTION: Because leaking steam or coolant can cause burns, allow the vehicle's cooling system to cool before performing this procedure.
36. Install the right front mudguard.
37. Install the engine guard. Refer to procedure: Engine Guard (501-02 Front Body Panels, Removal and Installation).
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