Reservoir Cap - Low Engine Coolant Level

Group: Engine Mechanical
Number: 95-20-001
Date: February, 1995
Model: 1995 Sonata

Subject:
Low Engine Coolant Level

DESCRIPTION:

A low radiator coolant level may be experienced without any signs of a coolant leak, but with an increase in the overflow reservoir level. These symptoms may be suggestive of a malfunctioning reservoir cap. Small pin holes in the reservoir cap can allow coolant to pass into the recovery bottle, but will not allow coolant to return to the radiator as it cools.

The engine coolant reservoir is located in the engine compartment on the passenger side of the vehicle between the headlight and battery. Instructions for replacement of the reservoir cap follow.

CAUTION:
Engine coolant may be extremely hot. Do not open the reservoir cap while the coolant is hot. Allow the vehicle to cool before performing this repair.

Coolant Reservoir:

1. Remove the reservoir cap from the reservoir.
2. Remove the inner reservoir hose "A" from cap. (There is no clip on this hose).
3. Remove the reservoir cap gasket "B". Discard old reservoir cap.
4. Install the gasket in the new cap.
5. Install the inner reservoir hose on the new cap.
6. Remove the overflow tube spring clamp and hose "C" from the old reservoir cap.
7. Install the overflow tube and clamp on the new reservoir cap. (Be sure the clamp is installed).
8. Inspect the new cap assembly to be sure the hoses and gaskets are properly fitted. Install cap securely on reservoir.