Coolant Replacement

1. Bring engine to normal operating temperature and turn engine off. With cooling system under pressure, inspect cooling system hoses and clamped hose connections for leaks, excessive deterioration, or contact wear. Inspect radiator installation retention. Note any discrepancies, and proceed.

2. Drain coolant as follows:

    WARNING: NEVER REMOVE RADIATOR OR COOLING SYSTEM CAP UNDER ANY CONDITIONS WHILE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE COOLING SYSTEM OR ENGINE.

    WARNING: TO AVOID BURNS FROM SCALDING COOLANT OR STEAM, USE EXTREME CARE WHEN REMOVING THE RADIATOR PRESSURE CAP.

   1. Switch the engine OFF and wait until cool. If radiator is still hot, carefully wrap a thick cloth around the cap and rotate slowly to the first stop. Step back until the pressure is released.
   2. Then press down on the cap and rotate until free. Remove the cap.
   3. Open radiator draincock and remove the cylinder block drain plug(s) to drain the coolant system.
      
      
      
      
   4. Disconnect overflow hose from radiator filler neck connection. Remove coolant recovery reservoir from fender apron and empty fluid. Flush reservoir with clean water, drain and reinstall reservoir and strap (if so equipped) and overflow hose and clamp to radiator filler neck.
   5. Correct/service/replace any components found to be malfunctioning in Step 1.

Cleaning

NOTE: Always remove the thermostat prior to pressure flushing. A pulsating or reversed direction flow of flushing water will loosen sediment more quickly than a steady flow in the normal direction of coolant flow. In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation, it will be necessary to use the pressure flushing method. Various types of flushing equipment are available.

To remove rust, sludge and other foreign material from the cooling system, use an appropriate cooling system flush such as Premium Cooling System Flush D6AZ-19A503-AA (ESE-M97B44-A and ESE-M97B43-A) or equivalent. Removal of such material restores cooling efficiency and avoids overheating.

Coolant Refill

Tools Required:

• Rotunda Battery and Anti-Freeze Tester 021-00046

1. Refill engine cooling system as follows:
   1. Close radiator draincock and install cylinder block drain plug(s).
   2. When refilling the cooling system, use equal parts of water and coolant as follows:

      Coolant Specification: Use only a permanent-type coolant such as Premium Cooling System Fluid E2FZ-19549-AA (ESE-M97B44-A and ESE-M97B43-A) or equivalent.

      Freeze protection may also be checked by using either a Rotunda Battery and Antifreeze Tester 021-00046 or equivalent, or a Hydrometer. A 50/50 mix of coolant concentrate and water will provide approximately -37°C (-35°F) protection, and provide the necessary anti-corrosion protection.

      On 2.3L only

   3. Disconnect heater hose at the connection on the thermostat housing.
   4. Fill radiator until coolant is visible at the connection in the thermostat housing or the coolant level in the radiator reaches the radiator filler neck seat.
   5. Install heater hose and install hose clamp.

      Refill the radiator to approximately 0 to 5 cm (0 to 2 inches) below the filler neck seat.

2. Operate engine until thermostat opens and the radiator upper hose becomes hot.

3. Stop the engine and add coolant up to the filler neck seat.

4. Install radiator pressure cap.

5. Add a 50/50 mixture of coolant and water to the FULL HOT mark on the coolant reservoir, to provide adequate cooling system fill. Install reservoir cap, if so equipped.