Cooling System Draining and Vacuum Filling
Cooling System Draining and Vacuum Filling
WARNING: To avoid having scalding hot coolant or steam blowing out of the cooling system, use extreme care when removing the coolant pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant pressure cap and turn it slowly until the pressure begins to release. Step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant pressure cap from the coolant expansion tank. Failure to follow these instructions may result in personal injury.
CAUTION: The engine cooling system must be maintained with the correct concentration and type of anti-freeze solution to prevent corrosion and frost damage. Failure to follow this instruction may result in damage to the vehicle.
CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.
1 Set the heater controls to maximum HOT.
2
WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.
Remove the coolant expansion tank cap.
3
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
4 Remove the front LH splash shield.
- Remove the 4 clips.
5 Remove the radiator access panel.
- Remove the 4 bolts.
6 Position a container to collect the fluid.
7 Disconnect the coolant hoses from the thermostat housing.
- Release the 2 clips.
- Allow the coolant to drain.
8 Remove the spare wheel and tire.
- Remove the tool kit.
- Access the winch.
9 Position a container to collect the fluid.
10 Disconnect the rear heater coolant hoses.
- Release the 2 clips.
- Allow the coolant to drain.
11 Connect the rear heater coolant hoses.
- Secure the clips.
12 Install the spare wheel and tire.
- Install the tool kit.
13 Connect the coolant hoses to the thermostat housing.
- Secure with the clips.
14 Prepare a sufficient amount of coolant to the specified concentration.
15 Install the cooling system vacuum refill adaptor to the expansion tank.
16 Install the vacuum filler gauge to the cooling system vacuum refill adaptor.
17 Install the venturi tube assembly to the vacuum filler gauge.
18
NOTE:
Make sure both valves on gauge assembly are in the closed position.
NOTE:
Small diameter or long airlines may restrict airflow to the coolant vacuum fill tool.
NOTE:
The coolant vacuum fill tool needs an air pressure of 6 to 8 bar (87 to 116 psi) to operate correctly.
Connect a regulated compressed air supply to the venturi tube assembly.
19
NOTE:
Make sure air cannot enter the hose.
Position the coolant pick-up pipe into a container of clean coolant.
20 Position the evacuated air hose into a container.
21 Open the air supply valve.
22 Open the coolant supply valve for 2 seconds to prime the coolant supply hose.
23 Apply air pressure progressively until the arrow on the vacuum filler gauge reaches the green segment.
24 Close the air supply valve.
25 Allow one minute to check the vacuum is held.
- Disconnect the compressed air supply.
26
NOTE:
Close the coolant supply valve when the coolant expansion tank MAX mark is reached or coolant movement has ceased.
Open the coolant supply valve and allow the coolant to be drawn into the system.
27 Remove the vacuum filler gauge and cooling system vacuum refill adaptor assembly.
28 Connect exhaust extraction hoses to the tail pipes.
29 Start and run the engine.
- Hold the engine speed at 2,500 RPM for 30 seconds.
- Return the engine to idle for 30 seconds.
- Repeat the above procedure a further 4 times.
30 Keep the coolant level in the expansion tank at the maximum level mark until a steady stream of coolant can be seen returning.
31
NOTE:
When the coolant bleed is complete and prior to installing the expansion tank cap, top-up the expansion tank to 30mm above the maximum level.
Install the coolant expansion tank cap.
32 Run the engine until the thermostat opens.
33 Switch the engine off and allow to cool.
34 Clean any spilt coolant from the vehicle.
35 Install the radiator access panel.
Tighten the 2 bolts to 10 Nm (7 lb.ft).
Tighten the 2 bolts to 62 Nm (46 lb.ft).
36 Install the front LH splash shield.
- Install the 4 clips.
37
WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.
Check and top-up the coolant if required.