Cooling System Draining and Filling

Cooling System Draining and Filling (2.0L LHU)

Warning

With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

Note: Use only a GM released anti-freeze mixture and ensure a concentration of 50 percent water to 50 percent antifreeze. Antifreeze does not just prevent the cooling system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should always be added, even in tropical countries.

In addition to the anti-freeze mixture,
water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of regenerated sea water is not suitable.

Damage may also be caused to the engine if unauthorized anti-freeze agent is used.

If radiator, cylinder head or cylinder head seal have been replaced the old coolant must not be re-used.

Cooling System Draining

1. Open cooling system. Unscrew coolant surge tank cap.






2. For draining the cooling system, open the drain screw (1) on the radiator.

Cooling System Filling

1. Vehicles with air condition, switch air conditioning off.

2. After draining the system, close the drain screw on the radiator.

3. Open cooling system. Unscrew coolant surge tank cap.





Note: To avoid that engine coolant gets into the generator, use a suitable tool to cover the generator.

4. Disconnect the quick fitting (1) on the T-connector of the engine feeding hose.




5. Insert a hose with a funnel (1) in the opening of the T-connector (2) and top up with coolant.

6. Connect the quick fitting bleeding hose to the T-connector of the engine feeding hose.




7. Top up coolant up to the bottom line of the bleed nozzle on the coolant surge tank (1).
When the coolant has stopped dropping top up the coolant until the bottom line of the down pipe hole (black arrow).

Note: After Engine Start top up coolant immediately until the bottom line of the down pipe hole (black arrow) and close cap.

Note: After removing the heater core (located in passenger room) the following additional work has to be done:

Kick the accelerator pedal 3 times immediately - thereby the engine speed should not exceed 2500 RPM.

8. Start the Engine

9. Warm up the engine.
Warm up engine at idle speed up to 2.500 RPM until radiator fan setting switches on.

Note: After removing the heater core (located in passenger room) let the engine run for further 2 minutes at 2.000-2.500 RPM. This ensures complete venting of the cooling system.

10. Vent cooling system
Kick the accelerator pedal 3 times - thereby the engine speed should not exceed 2.500 RPM.

11. Turn off the engine off and let the engine cool down.




12. Check coolant level and correct the coolant to welding area (1) if necessary.

13. After a test drive let the engine cool down and check the coolant level again. Adjust the coolant level to welding area (1) if necessary.