Coolant: Service and Repair
ENGINE COOLANT
Changing Engine Coolant
WARNING:
Do not remove the radiator cap when the engine is hot. Serious burns could occur from high-pressure engine coolant escaping from the radiator. Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.
DRAINING ENGINE COOLANT
1.Turn ignition switch ON and set temperature control lever all the way to HOT position or the highest temperature position. Wait 10 seconds and turn ignition switch OFF.
2.Remove the engine under cover using power tool.
3.Open the radiator drain plug at the bottom of the radiator, and remove the reservoir cap. This is the only step required when partially draining the cooling system (radiator only).
CAUTION:
- Perform this step when the engine is cold.
- Do not to allow the coolant to contact the drive belts.
4.When draining all of the coolant in the system for engine it is necessary to drain the cylinder block. Remove the RH cylinder block drain plug to drain the right bank, the oil cooler hose to drain the left bank as shown.
CAUTION:
Do not reuse copper sealing washers.
NOTE:
For Canada, the drain plug as shown is replaced by a block heater.
5.Remove the reservoir tank to drain the engine coolant, then clean the reservoir tank before installing it.
6.Check the drained coolant for contaminants such as rust, corrosion or discoloration.
If the coolant is contaminated, flush the engine cooling system. .
REFILLING ENGINE COOLANT
1.Close the radiator drain plug. Install the reservoir tank, cylinder block drain plug, and the oil cooler hose.
- The radiator must be completely empty of coolant and water.
- Apply sealant to the threads of the cylinder block drain plug.
Use Genuine High Performance Thread Sealant or equivalent.
Recommended Chemical Products And Sealants.
CAUTION:
Do not reuse copper sealing washers.
Radiator drain plug: .
RH cylinder block drain plug : .
2.Set the vehicle heater controls to the full HOT and heater ON position. Turn the vehicle ignition ON with the engine OFF as necessary to activate the heater mode.
3.Remove the vented reservoir cap and replace it with a non-vented reservoir cap before filling the cooling system.
4.Install the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attach the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter.
Tool number: KV-991J0070 (J-45695)
5.Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed position.
-Use recommended coolant or equivalent.
6.Install an air hose to the venturi assembly, the air pressure must be within specification.
Compressed air supply pressure
: 549 - 824 kPa (5.6 - 8.4 kg/cm2, 80 - 119 psi)
CAUTION:
The compressed air supply must be equipped with an air dryer.
7.The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process open the ball valve on the refill hose slightly. Rising coolant will be visible in the refill hose. After the refill hose is full of coolant, close the ball valve. This will purge air trapped in the refill hose.
8.Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations. Refer to the following table for expected vacuum readings.
Altitude above sea level Vacuum gauge reading
0 - 100 m (328 ft) : 28 inches of vacuum
300 m (984 ft) : 27 inches of vacuum
500 m (1,641 ft) : 26 inches of vacuum
1,000 m (3,281 ft) : 24 - 25 inches of vacuum
9.When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses vacuum. If the vacuum level drops, perform necessary repairs to the system and repeat steps 6 - 8 to bring the vacuum to the specified amount. Recheck for leaks.
10.Place the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero.
CAUTION:
Do not allow the coolant container to get too low when filling, to avoid air from being drawn into the cooling system.
11.Remove the Tool from the radiator neck opening and install the radiator cap.
12.Remove the non-vented reservoir cap.
13.Fill the cooling system reservoir tank to the specified level. Run the engine to warm up the cooling system and top up the system as necessary before installing the vented reservoir cap.
14.Install the engine under cover or skid plate. Service and Repair.
FLUSHING COOLING SYSTEM
1.Drain the water from the engine cooling system. Service and Repair.
2.Fill the radiator and the reservoir tank (to the "MAX" line), with water. Reinstall the radiator cap and leave the vented reservoir cap off.
3.Run the engine until it reaches normal operating temperature.
4.Press the engine accelerator two or three times under no-load.
5.Stop the engine and wait until it cools down.
6.Drain the water from the engine cooling system. Service and Repair.
7.Repeat steps 2 through 6 until clear water begins to drain from the radiator.