Repair instructions
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      Cooling - High Temperature
        Cooling Service Procedures
          DA-RM-04L001-00-001 - Drain/Fill fluid - Coolant
          DA-RM-04L001-01-001 - Remove/Install sensor - Coolant temperature
          DA-RM-04L001-01-002 - Remove/Install Hose - Header tank - Engine
        High Temperature Main Radiators and Fans
        Header Tank
      Cooling - Low Temperature
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Instructions
Chassis / Cooling - High Temperature / Cooling Service Procedures / DA-RM-04L001-00-001 - Drain/Fill fluid - Coolant
Preparation work
1.     
2.     
3.     
4.     
WARNING!
 
Risks of injury and poisoning when working with coolant!
When the engine is warm, the cooling system is pressurized. If the cooling system is opened suddenly, there is a risk of scalding from hot coolant which splashes out.
If coolant is swallowed, symptoms of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps can occur.
Wear protective gloves, protective clothing and eye protection.
•
Allow cooling system to cool down to a coolant temperature of less than 60 °C.
•
Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a screwed coolant cap approx. 1/2 turn and release the pressure.
•
Do not put coolant in beverage containers.
 
WARNING!
 
Possible fluid spills from vehicle systems during repairs or maintenance.
Risk of thermal incidents, slip hazards, corrosion of electrical components, failure of electrical or mechanical components or unwanted odours.
Always limit fluid spills and fully clean the spilled fluid after repairs or maintenance.
 
Drain fluid - Coolant
1.  
Remove coolant reservoir cap (1).
 
 
Care Point:
Make sure all relevant Personal Protective Equipment (PPE) is worn when carrying out this procedure (gloves, goggles, etc).
Care Point:
Use a suitable container to collect the coolant.
Container must be clean with no oil residue.
 
2.  
Detach clamps (2, 4).
 
3.  
Detach coolant hoses (3, 5) from water pump and front cover.
 
 
Care Point:
Use a suitable container to collect the coolant.
Container must be clean with no oil residue.
 
4.  
Remove clamp (6) right hand side and left hand side.
 
5.  
Detach coolant hoses (7) right hand side and left hand side from low temperature radiator.
 
Fill fluid - Coolant
 
Care Point:
Inspect collected coolant, carry out step one only if the following applies.
 
1.   
If oil found in coolant, flush system using suitable flushing agent.
When pressurising system using displacement tool tank (16) complete an extensive check for coolant leaks, particularly around the following areas:
Engine oil cooler and Vee area
Water pump
Oil pump
Transmission oil cooler and pipes
Clutch oil cooler and pipes
 

 
Care Point:
Renew clips on coolant hoses.
Make sure clip is positioned just outside the positioning mark (furthest from engine block).
 
2.   
Install all coolant hoses in reverse order.
 
 
Care Point:
Maximum fill on a dry vehicle is 25 litres of coolant (mix ratio of 50:50 with water).
Care Point:
Care Point:
Make sure vacuum box is in a higher position than the coolant reservoir throughout the filling procedure.
Care Point:
Make sure all relevant Personal Protective Equipment (PPE) is worn when carrying out this procedure (gloves, goggles, etc).
 
3.   
Attach adaptor to coolant reservoir (8).
 
4.   
Connect vacuum box Vacuum Fill Tool - Coolant to coolant fill adaptor (9).
 
5.   
Close all valves on vacuum box (11) (Venturi 10, Top 14, Lower 12, Fill 13).
 
6.   
Attach air line to top box connection (14).
 
7.   
Open top and lower valves on the vacuum box (14, 12).
 
 
Care Point:
Do not exceed a vacuum of 0.5 bar vacuum at this stage.
 
8.   
Gradually open Venturi valve (10) on vacuum box to generate vacuum in system.
 
 
Care Point:
Vacuum should not drop once top valve (14) is closed. If the vacuum cannot be held, please check system for leaks.
 
9.   
Close top valve (14) and Make sure system can hold a vacuum.
 
10.  
Release vacuum by closing Venturi valve (10) and opening top valve (14).
 
11.  
Close lower valve (12).
 
 
Care Point:
Place open end of filler tube in to separate coolant filled container. Please Make sure a minimum of 10 litres of coolant (50:50 mix with water) is in the separate container.
 
12.  
Connect filler tube (15) to fill valve (13).
 
13.  
Open filler valve (13).
 
 
Care Point:
Only fill vacuum box to half way point.
 
14.  
Gradually open Venturi valve (10) to draw coolant mix into vacuum box.
 
15.  
Close Venturi valve (10) and fill valve (13) once vacuum box is half full.
 
16.  
Remove filler tube (15).
 
17.  
Open lower valve (12).
 
 
Care Point:
Make sure vacuum box fill level does not exceed sight level.
Care Point:
During this stage of the procedure do not exceed 0.8 bar vacuum.
 
18.  
Gradually open Venturi valve (10) to draw air out of vehicle coolant system. Continue until no bubbles can be seen in the hose connecting the vacuum box to the coolant reservoir, or the box becomes full.
 
19.  
Close Venturi valve (10) and allow coolant to be drawn into the vehicle.
 
20.  
Repeat steps 10 – 20.
 
21.  
Detach equipment from vehicle.
 
22.  
Drain all coolant from vacuum box.
 
23.  
Repeat steps 3 - 11.
 
 
Care Point:
Make sure vacuum box fill level does not exceed sight level.
Care Point:
During this stage of the procedure do not exceed 0.8 bar vacuum.
 
24.  
Repeat steps 18 – 20 using a completely empty vacuum box.
 
25.  
Disconnect vacuum box (11) from vehicle.
 
 
Care Point:
Make sure pressure inlet valve (17) is closed.
 
26.  
Fill displacement tool tank (16) with 2.5 litres of coolant. Kit - Coolant Displacement Test
 
27.  
Attach displacement tool adaptor (18) to coolant reservoir (8).
 
28.  
Attach displacement tool tank (16) to displacement tool adaptor (18).
 
29.  
Attach hand pump to pressure inlet valve (17).
 
 
Care Point:
Pressurise to 1 bar of pressure.
Do not exceed 1 bar.
 
30.  
Pressurise coolant system using hand pump .
 
 
Care Point:
Coolant displacement must not exceed 800 ml.
 
31.  
Read displacement tool tank (16) gauge, Make sure coolant level is not displaced more than 800 ml.
 
32.  
If coolant level displacement is below 800 ml, proceed to step 35.
 
33.  
If coolant level displacement exceeds 800 ml, repeat steps 3 - 20 and re-test.
 
34.  
Record the amount of coolant added to vehicle pre-run up and pressure displacement level.
 
 
Care Point:
The displacement tool must be de-pressurised before disconnecting from header tank or re-filling.
 
35.  
De-pressurise displacement tool by pressing the pressure release valve on the hand pump.
 
36.  
Remove equipment.
 
37.  
Once vehicle has been filled, carry out a short vehicle run up and repeat process.
 
 
Care Point:
Top up coolant reservoir, Make sure fill level is between MIN and MAX.
 
38.  
Record final amount of coolant added to vehicle post-run up and pressure displacement level.
 
 
Care Point:
Replace any clips, seals or fixings as required.
 
39.  
Install components in reverse order.
 
   
   
   Note