DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

Normal warranty policy and procedures apply.
Material allowance is included in labor operation.

REPAIR PROCEDURE

REPAIR RADIATOR TO EXPANSION TANK COOLANT BLEED TUBE

1. Open the hood.

2. Place a container under the front of vehicle to catch any coolant spillage.

3. Release the two clamps at either end of the coolant bleed tube connecting the expansion tank and the radiator.

4. Release the coolant bleed tubing from two locating clips on the inner fender.

5. Disconnect the ends of the coolant bleed tube and remove it from the vehicle.

6. Remove the original coolant bleed tube clamps (ESR2222) and install them onto the new coolant bleed tube.

7. Fit the new coolant bleed tube to the radiator and the expansion tank.

8. Secure the new tubing with the pre-positioned reused clamps.

9. Secure the coolant bleed tube into the locating clips on the inner fender

10. Check and if necessary top up the cooling system.

INSTALL BATTERY VENT PIPE KIT

CAUTION:
The battery and the charging system must be operating correctly to ensure the corrective actions in this bulletin are effective.

1. Evaluate the battery and the charging system and ensure the charging system is operating correctly.

2. Remove the blanking plug from the inner fender, adjacent to the battery. (Arrowed in Figure 1)

NOTE:
The vent pipe kit will have to be connected to either the front or side of the battery depending on the type of battery installed. (Inset in Figure 2 or Figure 3)

3. Connect the new vent pipe to the battery breather outlet.

4. Drill a 10 mm hole in the center of the blanking plug. (Arrowed in Figure 4).

5. Insert approximately 60 mm (2 inches) of the vent pipe through the hole in the blanking plug.

6. Route the vent pipe along the newly installed coolant bleed tube and position the blanking plug next to its location in the inner fender.

7. Determine the amount of vent pipe required for the installation and adjust the initially inserted length of pipe as required to avoid excess vent piping in the engine compartment.

8. When the correct length has been determined, cut the vent pipe at approximately 30 mm (1-1/4 inch) beyond the grommet. (Figure 4).

9. Insert the vent pipe through the inner fender and install the blanking plug in the inner fender opening from which it was removed. (Figure 5)

10. Secure the vent pipe to the coolant bleed tubing with a tie strap. (Figure 6)

11. Ensure the battery cover is properly positioned and secure and that all hoses and wires are properly routed.

12. Close the hood.

Cooling System - Coolant Leak From Bleed Tube