Cooling System Draining, Filling and Bleeding

Cooling System Draining, Filling and Bleeding

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.

CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

1. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Position the vehicle on a lift.
2. Set the heater controls to maximum.
3. Disconnect the battery ground cable.
4. Remove the engine cover.

5. 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.

Remove the coolant expansion tank cap.





6. Remove the engine undershield.
7. Drain the coolant.
^ Position a container to collect the fluid.
^ Attach a hose to the radiator drain tap. Open the tap.





8. Close the radiator drain tap and remove the hose.
^ Remove the container.
9. Connect the battery ground cable.
10. Connect exhaust extraction hoses to the tail pipes.

11. CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

CAUTION: Damage to the charge air cooler coolant pump will occur if the pump is allowed to cavitate.

Stage 1. Top-up and bleed the cooling system.
^ Remove the coolant expansion tank cap.
^ Add coolant to the expansion tank as required.
^ Start and run the engine.
12. When coolant runs from the expansion tank, bubble free, tighten the bleed screw.

13. CAUTION: Observe the engine temperature gauge. If the engine starts to over-heat switch off immediately and allow to cool. Failure to follow this instruction may cause damage to the vehicle.

Stage 2. Set the heating system to MAX heat, the blower motor to MAX speed and the air distribution to the instrument panel registers.
^ Add coolant to the expansion tank as required.
^ Install the coolant expansion tank cap.
^ Loosen the coolant expansion tank bleed screw.
^ Start and run the engine.
^ Allow the engine to run until hot air is emitted from the instrument panel registers, while observing the engine temperature gauge.





14. Switch the engine off and allow to cool.
15. Check for leaks and then fill the coolant expansion tank to the MAX mark.





16. Install the engine cover.
17. Clean any spilt coolant from the vehicle.
18. Install the engine undershield.
19. Disconnect the exhaust extraction hoses from the tail pipes.