Attachment III - Technical Information
SERVICE PROCEDURE1. WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS RUNNING OR WHEN THE COOLING SYSTEM IS HOT. PERSONAL INJURY OR DAMAGE TO THE COOLING SYSTEM COULD RESULT.
CAUTION:
The coolant must be recovered in a suitable, clean container for reuse. Do not contaminate the accessory drive belt with coolant while performing this procedure.
Partially drain the cooling system.
^ Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn counterclockwise. When the pressure is released, remove the cap.
^ Place a suitable container below the radiator draincock and partially drain the cooling system. Once the system is sufficiently drained, close the radiator draincock.
2. Remove the three (3) push-type fasteners securing the engine appearance cover, then remove the cover from the engine. See Figure 1.
3. Remove the air cleaner outlet tube. See Figure 1.
^ Disconnect the intake air temperature sensor electrical connector.
^ Disconnect the three (3) hoses.
^ Remove the support nut and washer.
^ Loosen the two (2) hose clamps and remove the air cleaner outlet tube.
4. Place shop towels under the thermostat housing to prevent coolant from going down into the engine valley. Then remove the three (3) bolts securing the thermostat housing cover. See Figure 2.
5. Position the thermostat housing cover out of the way, then remove the thermostat and gasket from the thermostat housing. See Figure 3.
6. NOTE: Clean the gasket sealing surfaces before assembly.
Install the new gasket onto the new thermostat. Then install the new thermostat and gasket into the thermostat housing.
7. Position the thermostat housing cover and install the three (3) bolts. Tighten the bolts to 11 Nm (8 lb-ft). Remove the shop towels and make sure no coolant has gone down into the engine valley.
8. Install the air cleaner outlet tube.
^ Tighten the two (2) hose clamps to 5 Nm (45 lb-in).
^ Install the support nut and washer.
^ Connect the three (3) hoses.
^ Connect the intake air temperature sensor electrical connector.
9. WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS RUNNING OR WHEN THE COOLING SYSTEM IS HOT. PERSONAL INJURY OR DAMAGE TO THE COOLING SYSTEM COULD RESULT.
CAUTION:
Do not contaminate the accessory drive belt with coolant while performing this procedure.
Fill and bleed the engine cooling system:
^ Remove the engine fill cap.
^ Open the heater air bleed.
^ Add coolant to the degas bottle allowing the system to equalize until no more coolant can be added.
^ Install the degas bottle cap.
^ Add as much coolant as possible to the engine fill. The heater air bleed will remain open.
^ Install the engine fill cap. Tighten the cap to 9 Nm (80 lb-in).
^ With the heater air bleed open, start the engine and turn the heater to the MAX position.
^ Close the heater air bleed once a steady stream of coolant flows from it during engine idle.
^ Allow the engine to idle for five minutes and add coolant to the degas bottle as needed to maintain the cold fill MAX mark.
^ Partially open the heater air bleed to release any entrapped air and close it again.
^ Maintain an engine speed of 2,000 rpm for 3-5 minutes, or until hot air comes from the heater.
^ Return the engine to idle and verify that hot air is still coming from the heater.
^ Set the heater temperature to 24°C (75°F) and allow the vehicle to idle for two minutes.
^ Shut the engine off and allow it to cool.
^ After the engine has cooled, add coolant to the degas bottle to bring the level to the cold fill MAX mark.
10. Position the engine appearance cover and install the three (3) push-type fasteners.
PREPARE AUTHORIZED MODIFICATIONS LABEL
1. Obtain and prepare the Authorized Modifications label. Write the modification completed, your P&A code, date of repair and the recall program number in the spaces provided on the label. See Figure 4.
2. Open the hood and clean an area of the radiator support with isopropyl alcohol and a clean cloth.
3. Apply the label to the clean area.
4. Provide California and Massachusetts owners with a completed Emissions Recall-Proof of Correction certificate. See Figure 5.