Cooling System: Service and Repair

Fig. 36 Steel Wire Installation:

1. Set heater temperature control level to Maximum heat position.
2. Remove radiator filler cap, air relief plug and air bleeder cap.
3. Fill radiator with coolant and fill reservoir tank to Max line with coolant.
4. Reinstall air relief valve once coolant spills from air relief hole during refill.
5. Fill radiator and reservoir tank with coolant.
6. Reinstall air bleeder cap.
7. Install a temporary radiator filler cap which allows air and coolant in cooling system to be directed into reservoir tank regardless of pressure.
8. Install a suitable steel wire between negative pressure valve and its seat as shown in Fig. 38.
9. Warm engine to normal operating temperature.
10. Run engine at 2500 RPM for ten seconds and return to idle speed.
11. Repeat above steps two or three times.
12. Stop engine and allow to cool.
13. Remove temporary radiator filler cap and check coolant level.
14. If necessary, refill radiator up to filler neck with coolant.
15. Refill reservoir tank to Max line with coolant.
16. Repeat steps 10 through 15 two or more times.
17. Install a proper radiator filler cap, then warm engine and check for sound of coolant flow while running engine from idle up to 4000 RPM with heater lever set at several positions between Hot and Cold.
18. If sound is heard, bleed air from cooling system according to following steps:
a. Cool engine and remove air bleeder cap on heater inlet hose.
b. Attach a suitable transparent hose at air bleeder pipe and put opposite end of hose into coolant reservoir tank.
c. Install temporary radiator filler cap and check for proper connection of all coolant related hoses.
d. Start engine and check for bubbles in reservoir tank.
e. Set heater control lever to MAX COOL position in order to bypass coolant through the transparent hose.
f. Run engine up to 2300 RPM until bubbles disappear in transparent hose. Do not run engine over 2300 RPM. Engine may be damaged due to reduced coolant flow.
g. After removing bubbles, set heater temperature control lever to max HOT position and check for sound of coolant flow.
h. If sound is heard, repeat steps E through G.
i. Stop engine and allow to cool.
j. Install a proper radiator filler cap, remove transparent hose and install air bleeder cap.
k. Check any removed parts for secure installation.