Engine Cooling System: Maintenance Suzuki XL7 I

Draining and Filling Cooling System (LY7 GE 47716 Fill)

Special Tool

1. J 26568 Coolant and Battery Fluid Tester
2. GE-47716 Vac N Fill Coolant Refill Tool
3. J 42401 Radiator Pressure Adapter

Draining Procedure

Scheme 81

Note. A 7.6 liter (8 qt) coolant container will be needed.

Scheme 82

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1. Place the coolant container under the radiator drain cock located at the bottom of the right radiator end tank.
2. Open the drain valve to start the flow of coolant. Coolant will drain slowly until the surge tank cap is removed.
3. Remove the surge tank cap from the surge tank. Allow the coolant to drain from the system.
4. Close the drain valve once the coolant has drained from the radiator.
5. Additional coolant can be drained from the engine by removing the engine block drain plug.
6. Install the engine block drain plug once the coolant has drained from the engine.
7. Inspect the coolant.
8. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-follow the filling procedure. Discolored-follow the flush procedure. Refer to «COOLANT SYSTEM FLUSHING»(ref-268430-S05691710942007102300000) .

Vac-N-Fill Procedure

Note. To prevent boiling of the coolant/water mixture in the vehicle's cooling system, do not apply vacuum to a cooling system above 49° C (120° F). The tool will not operate properly when the coolant is boiling.

Scheme 84

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1. Install J-42401-2 into the surge tank fill neck.
2. Install J-42401-3 to the surge tank fill neck.
3. Attach the Vac N Fill cap to the J-42401-3.
4. Attach the vacuum gauge assembly to the Vac N Fill cap.
5. Attach the fill hose to the barb fitting on the vacuum gauge assembly. Ensure that the valve is closed. NOTE: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water. Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.
6. Pour the coolant mixture into the graduated reservoir.
7. Place the fill hose in the graduated reservoir. NOTE: Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.
8. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
9. Attach the venturi assembly to the vacuum tank.
10. Attach a shop air hose to the venturi assembly. Ensure the valve on the venturi assembly is closed.
11. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
12. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
13. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
14. To aid in the fill process, position the graduated reservoir above the surge tank.
15. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
16. Close the valve on the venturi assembly.
17. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss. If vacuum loss is observed, refer to «LOSS OF COOLANT»(ref-268430-S42633239872007102300000) .
18. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
19. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 12 - 18 .
20. Detach the Vac N Fill cap from the J-42401-3.
21. Remove J-42401-2 from the surge tank fill neck.
22. Add coolant to the system as necessary.
23. Inspect the concentration of the coolant mixture using J 26568. NOTE: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.
24. Detach the vacuum hose from the vacuum gauge assembly.
25. Attach the extraction hose to the vacuum hose.
26. Open the valve on the venturi assembly to start a vacuum draw.
27. Use the extraction hose to draw out coolant to the proper level.
28. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.

Scheme 98

Note. A 7.6 liter (8 qt) coolant container will be needed.

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1. Place the coolant container under the radiator drain cock.
2. Remove the surge tank cap from the surge tank and the coolant will drain from the system.
3. If necessary drain the engine block.
4. Inspect the coolant.
5. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-follow the filling procedure. Discolored-follow the flush procedure. Refer to «COOLANT SYSTEM FLUSHING»(ref-268430-S05691710942007102300000) .

Flushing

Note. Do not use a chemical flush. Store used coolant in the proper manner, such as in a used engine coolant holding tank. Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical. Do not dispose of coolant into the sewer system or ground water. This is illegal and ecologically unsound. Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a back flusher, follow the manufacturer's instruction. Always remove the thermostat before flushing the cooling system.

When the cooling system becomes contaminated, the cooling system should be flushed thoroughly to remove the contaminants before the engine is seriously damaged.

1. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .
2. Remove the surge tank. Refer to «REMOVAL PROCEDURE»(ref-268430-S18016005542007102300000) .
3. Clean and flush the surge tank with clean, drinkable water.
4. Install the surge tank. Refer to «INSTALLATION PROCEDURE»(ref-268430-S08719571642007102300000) .
5. Follow the drain and fill procedure using only clean, drinkable water. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .
6. Run the engine for 20 minutes.
7. Stop the engine.
8. Drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .
9. Repeat the procedure if necessary, until the fluid is nearly colorless.
10. Fill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .

Scheme 101

Scheme 102

1. Partially drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .
2. Remove the heater pipe inlet hose (1) from the heater inlet pipe.
3. Remove the heater inlet pipe housing bolts (1).
4. Remove the housing.
5. Remove the heater inlet pipe housing seal. Discard seal.

Scheme 103

1. Install a NEW heater inlet pipe housing seal. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the heater inlet pipe housing bolts (1). Tightening torque Tighten the heater inlet housing bolts to 10 N.m (89 lb in) .
3. Install the heater inlet hose (1) to the heater inlet pipe.
4. Refill the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .

Scheme 104

Scheme 105

1. Partially drain the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (LY7 GE 47716 FILL)»(ref-268430-S24316590782007102300000) and «DRAINING AND FILLING COOLING SYSTEM (LY7 STATIC FILL)»(ref-268430-S04688222192007102300000) .
2. Remove the heater pipe outlet hose (1) from the heater outlet pipe.
3. Remove the heater inlet pipe. Refer to «REMOVAL PROCEDURE»(ref-268430-S13843973562007102300000) .
4. Remove the heater outlet pipe (1).
5. Remove the heater outlet pipe O-ring (2). Discard O-ring.

Scheme 106

1. Install a NEW heater inlet pipe O-ring. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the heater outlet pipe (1).
3. Install the heater outlet hose (1) to the heater outlet pipe.
4. Install the heater inlet pipe. Refer to «INSTALLATION PROCEDURE»(ref-268430-S40423153682007102300000) .

Scheme 107

CALLOUT COMPONENT NAME TABLE

Scheme 108

CALLOUT COMPONENT NAME TABLE