Filling Cooling System

FILLING COOLING SYSTEM - 2.0L/2.4L ENGINE





WARNING: Make sure engine cooling system is cool before removing pressure cap or any hose. The cooling system is pressurized when hot. Severe personal injury may result from escaping hot coolant.

CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 mixture of the recommended ethylene glycol and distilled water is recommended. For recommended coolant usage,.

1. Close radiator draincock. Hand tighten only.
2. Open, but do not remove cooling system bleed valve.
3. Attach a 6.35 mm (0.250 in.) inside diameter clear hose that is 120.0 cm (48 in.) long to the bleed valve. Route the hose away from the accessory drive belts and radiator fan. Position the other end of the hose into a clean collecting container. The hose will prevent coolant from contacting the accessory drive belts, A/C compressor, and other components.





NOTE: Be careful not to spill coolant on drive belts or the generator.

NOTE: While filling the cooling system, pour coolant into the larger section of the Filling Aid Funnel 8195.

4. Remove the cooling system pressure cap. Install Special Tool 8195 Filling Aid Funnel (1).
5. Use the supplied clip (2) to pinch overflow hose.




6. Slowly fill the cooling system until a steady stream of coolant flows from the attached hose on the bleed valve.
7. Close the bleed valve and remove the hose.




8. Remove clip (2) from overflow hose and allow Filling Aid Funnel 8195 to drain through overflow hose. Remove Filling Aid Funnel 8195 (1).
9. Fill coolant to the top of the pressure cap neck.
10. Install cooling system pressure cap.

CAUTION: Coolant may leak out of the bottle overflow tube if filling too rapidly.

11. Slowly fill coolant reserve/recovery bottle to at least the FULL HOT mark with the recommended coolant. It may be necessary to add additional coolant to the reserve/recovery bottle after three or four warm-up/cool down cycles to maintain coolant level between the FULL HOT and ADD marks. This is due to the removal of trapped air from the system.