DRAINING & REFILLING COOLING SYSTEM
| WARNING | DO NOT remove expansion tank pressure cap, coolant drain plugs or bleed screws when engine is hot, and especially if it is overheated. Serious injury such as scalding can be caused by escaping steam or hot coolant. Allow engine to cool before attempting coolant cap or plug removal. |
Cooling System Draining
- Remove engine acoustic cover. Visually check engine and cooling system for signs of coolant leaks. Examine hoses for signs of cracking, distortion and security of connections.
- Remove expansion tank filler cap. Remove underbelly panel. See «UNDERBELLY PANEL»(ref-167962-S16909190662004102800000) under REMOVAL & INSTALLATION. Position container to collect coolant.
- Remove cylinder block drain plug. (Scheme 17) Release clip and remove bottom hose from radiator. Allow cooling system to drain.
Scheme 17
Cooling System Refill
- Flush system with water under low pressure. Clean cylinder block drain plug and apply sealant, Part No. STC 50552 to first 3 threads. Install cylinder block drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-167962-S03090243932004102600000).
- Install bottom hose to radiator and secure with clip. Prepare coolant to required concentration. See «COOLING SYSTEM CAPACITY»(ref-167962-S26433327542004102800000).
- Remove bleed screw from heater return hose. (Scheme 18) Slowly fill cooling system through coolant expansion tank until a steady flow of coolant is emitted from the bleed hole. Install and close bleed screw in heater return hose.
- Continue to fill system through expansion tank until coolant reaches base of expansion tank bleed hose. Install expansion tank filler cap.
- Start and run engine at idle speed for 5 minutes. Turn off engine. Squeeze bottom hose several times to remove any trapped air. Start engine and run at speeds varying between idle speed and 3500 RPM for 7 minutes. Switch off engine and allow to cool.
- Remove expansion tank filler cap and add coolant until it reaches expansion tank MAX mark. Install expansion tank filler cap. Start and run engine until normal operating temperature is reached. Unsure bottom hose is warm or hot indicating thermostat is fully open.
- Ensure warm air is available at vents. If warm air is not available, an air lock may be present in heater matrix. If necessary, allow engine to cool, remove expansion tank filler cap and repeat bleed operation at heater hose.
- Turn off engine and allow to cool. Check for leaks and top-up coolant to expansion tank MAX mark. Install underbelly panel. See «UNDERBELLY PANEL»(ref-167962-S16909190662004102800000) under REMOVAL & INSTALLATION. Install engine acoustic cover.
Scheme 18
