Cooling System Filling

COOLING SYSTEM FILL - OM651

WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury.

CAUTION: Only use the recommended ethylene glycol and distilled water at a 50/50 mixture.





1. Close the drain cock.
2. Pinch the overflow tube off.
3. Remove the cooling system pressure cap. Install the Filling Aid Funnel, Tool 8195.
4. Open the bleeder valve in the heater return hose and elevate the valve with the top of the engine cover.
5. Overfill the coolant recovery container till the Filling Aid Funnel is half full. Watch for the coolant to bleed out from the bleeder valve.
6. Close the bleeder valve when coolant is present.
7. Squeeze the upper radiator hose to help in moving the air out of the cooling system.
8. If necessary, Add coolant to the recovery container. Fill to the full line.

WARNING: All air must be purged from the 2.2L engine when refilling the cooling system. Failure to do so can cause EGR Cooler cracking which can lead to catastrophic engine and exhaust system damage.





9. With the HVAC system off. Start the engine and allow the engine to run continuously at 1600 ERPM's for minimum of ten minutes.
10. Squeeze the hoses (1) located at the EGR (2) to aid in moving the air through the EGR.
11. Increase the engine RPM's to 2000 and hold till the thermostat opens. Upper radiator hose should be warm to touch.
12. Return the engine to idle. Add coolant to the recovery container as the air is purged from the cooling system. Fill to the full line.
13. Shut the engine off. Allow the engine to cool.
14. Slowly open the bleeder valve on the heater hose to purge any trapped air.
15. If necessary, Add coolant to the recovery container 1cm above the fill line.
16. Remove the funnel and replace the pressure cap on to the recovery container.