System Filling
SYSTEM FILLING - GAS ENGINE
1.6L 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.
1. Close radiator draincock. Hand tighten only.
2. Remove cooling system pressure cap. Install Tool 8195 Filling Aid Funnel (1).
3. Use the supplied clip to pinch overflow hose (2) that connects between the radiator and the coolant recovery container.
4. Place a piece of clear 6.35 mm (0.250 in.) I.D. tubing 305 mm (12 in.) long over the cooling system bleed screw (1) nipple. The cooling system bleed screw is located in the heater hose (2) near the coolant recovery container.
5. Open, but do not remove, the cooling system bleed screw (1).
NOTE: While filling the cooling system, pour coolant into the larger section of the Filling Aid Funnel 8195.
6. Slowly fill the cooling system with coolant, , until a continuous stream of coolant begins to flow out of the hose.
7. Close the cooling system bleed screw (1) and remove the tubing.
8. Remove clip from overflow hose (2) and allow Filling Aid Funnel 8195 (1) to drain through overflow hose into coolant bottle. Remove Filling Aid Funnel 8195 (1).
9. Install cooling system pressure cap.
10. Slowly fill the coolant recovery container to the FULL HOT mark with the recommended coolant. It may be necessary to add coolant to the recovery container after one warm-up/cool down cycle in order to maintain the coolant level between the FULL HOT and ADD marks. This is due to the removal of trapped air from the system.
2.0/2.4L ENGINE
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 recovery container 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.