Cooling System: Service and Repair

Drain and Refill

Service Repair No - 26.10.01

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.

Drain

1. Visually check engine and cooling system for signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion and security of connections.
3. Position drain tray to collect coolant.
4. Remove expansion tank filler cap.









5. Remove drain plugs from LH and RH sides of cylinder block and allow cooling system to drain.





6. Disconnect bottom hose from radiator and allow cooling system to drain.

Refill

1. Flush system with water under low pressure. Do not use water under high pressure as it could damage the radiator.
2. Apply Loctite 577 to cylinder block drain plugs. Fit drain plugs to cylinder block and tighten to 30 Nm (22 ft. lbs.).
3. Connect bottom hose to radiator and secure with hose clip.
4. Prepare coolant to required concentration.
5. Remove bleed screw from top hose.
6. Slowly fill the system through the coolant expansion tank until a steady flow of coolant is emitted from the bleed hole.
7. Fit the bleed screw, then continue filling the system until coolant level reaches 'MAX' mark on expansion tank.
8. Fit expansion tank filler cap.
9. Start and run engine until normal operating temperature is reached.
10. Switch off engine and allow to cool.
11. Check for leaks and top-up coolant to 'MAX' mark on expansion tank