Cooling System: Service and Repair

1. Turn ignition switch On and set front temperature control knob to full warm position.

NOTE: On vehicles with rear heater, ensure that rear blower switch is in any position except Off.

Engine Air Relief Plug Location:

2. Loosen engine air relief plug, Fig. 27, then the radiator air relief plug three turns.

NOTE: Do not remove radiator air relief plug.

Heater Pipe Air Relief:

3. Remove air duct, then loosen heater pipe air relief clamp and remove cap, Fig. 28.
4. Install a hose to heater pipe air relief tube, then add a 50/50 mixture of coolant and water to MAX mark on coolant reservoir.
5. Install other end of hose in coolant reservoir.

NOTE: Ensure that hose end is submerged in coolant at all times.

6. Place a drain pan under radiator relief plug opening, then slowly pour a 50/50 mixture of coolant into radiator, allowing several minutes for air to escape.
7. Fill radiator with coolant until coolant starts to drip from radiator air relief plug opening, then close plug, tightening to specifications.
8. Pour more coolant into radiator while gently moving moving upper radiator hose up and down.

Installing Wire On Radiator Pressure Cap:

9. Install a wire under radiator pressure cap negative pressure valve, Fig. 29, to allow flow of air and coolant regardless of pressure. Do not install cap at this time.
10. With engine air relief plug off, radiator pressure cap off, and selector lever in P position, start and run engine at 2000 RPM until lower radiator hose becomes hot, indicating thermostat has opened.

NOTE: If coolant comes out of engine air relief plug, close it. If coolant level in radiator filler neck lowers, add coolant, If coolant overflows from radiator filler neck, install radiator pressure cap (with wire installed).

11. Close engine air relief plug if it is not already closed, then stop engine and allow to cool down completely.
12. Refill radiator and coolant reservoir as necessary, then install radiator pressure cap (with wire installed) and again warm engine to normal operating temperature.
13. Observe temperature gauge closely. If gauge begins to rise above normal, stop engine and allow to cool down completely, then refill radiator and coolant reservoir as necessary.
14. On models less rear heater, run engine at 3000 RPM with temperature control knob in full warm position for five minutes or until outlet air is hot.

NOTE: Keep coolant reservoir at MAX level. Repeat procedure three times to ensure no air is trapped in system.

15. On models with rear heater, run engine at 3000 RPM with front temperature control knob in full cool position and front and rear blower switches in any position but Off, for five minutes or until rear outlet air is hot.

NOTE: Repeat procedure three times to ensure no air is trapped in system.

16. Turn rear blower switch to Off position, front temperature control knob to full warm position until front outlet air is hot.
17. On all models, stop engine, then pour coolant mixture into coolant reservoir to MAX level.
18. Allow engine to cool down, then remove radiator pressure cap.
19. Remove wire and reinstall radiator pressure cap, then remove hose from heater pipe air relief tube and quickly reinstall cap and clamp.
20. Install air duct.