Draining and Filling Cooling System of Motor ARE

(Drenando y Llenando Sistema de Enfriamiento con Motor ARE)

Special tools and workshop equipment required
t Adapter for cooling system tester !"A"# $%&'()
t *ipe for cooling system tester !"A"# $%&'($+
t ,ose clip pliers !"A"# $-%$
t .ooling system charge unit !AS /+-/
t Drip tray for workshop hoist !AS /%+)
t Refractometer 0$+++&


Draining
.ollect drained coolant in a clean container for reuse or disposal"
1AR232#
,ot steam(hot coolant can escape risk of scalding"
t 0he cooling system is under pressure when the engine is hot"
t 0o allow pressure to dissipate4 co5er filler cap on e6pansion tank with cloth and open
carefully"
7 8pen filler cap on e6pansion tank"
7 Release fasteners arrows and remo5e noise insulation"

7 *lace drip tray for workshop hoist !AS /%+) 9eneath engine"
7Lift retaining clip arrow and disconnect coolant hose (9ottom right) from radiator"


7 Also disconnect coolant hose at oil cooler arrow4 and drain off remaining coolant"
:illing
2ote
0he cooling system is filled all year round with a mi6ture of water and radiator
antifree;e(anticorrosion agent"
t <se only the radiator antifree;e(anticorrosion agent appro5ed for this engine"
t 8ther coolant additi5es could seriously impair in particular the anticorrosion
properties" 0he resulting damage could lead to loss of coolant and consequently to
serious engine damage"
0he specified radiator antifree;e(anticorrosion agent pre5ents frost and corrosion
damage and stops scaling"
t Such additi5es also raise the 9oiling point of the coolant" :or these reasons the cooling
system must 9e filled all year round with the correct antifree;e and anticorrosion
additi5e"
t =ecause of its high 9oiling point4 the coolant impro5es engine relia9ility under hea5y
loads4 particularly in countries with tropical climates"
t :rost protection is required down to a9out 7%> ?. (in countries with arctic climate@
down to a9out 7A> ?.)" 0he coolant concentration must not 9e reduced 9y adding water
e5en in warmer seasons and in warmer countries" 0he antifree;e concentration must 9e
at least '+ B"
t 3f greater frost protection is required in 5ery cold climates4 the concentration of
radiator antifree;e(anticorrosion agent can 9e increased4 9ut only up to /+B (this gi5es
frost protection to a9out 7'+ ?.)" 3f the concentration e6ceeds /+B4 frost protection
decreases again and cooling efficiency is also impaired"

t <se only clean tap water for mi6ing coolant"
t Do not use drained coolant again if@ the radiator4 heat e6changer for heater4 cylinder
head4 cylinder head gasket or cylinder 9lock ha5e 9een renewed" Also if the coolant is
contaminated or dirty"
t :or checking antifree;e protection in cooling system4 use refractometer 0$+++&"

7 .onnect coolant hose to oil cooler arrow"
7 .onnect coolant hose arrow with plugin connector to radiator"

7:ill reser5oir of cooling system charge unit !AS /+-/ with at least $+ litres of
premi6ed coolant (according to recommended ratio)@
l Radiator antifree;e(anticorrosion agent ('+ B) and water (/+ B) for frost protection
to 7%> ?."
l Radiator antifree;e(anticorrosion agent (>+ B) and water (>+ B) for frost protection
to 7A> ?. Radiator antifree;e(anticorrosion agent (/+ B) and water ('+ B) for frost
protection to 7'+ ?."
l Radiator antifree;e(anticorrosion agent"
7:it adapter for cooling system tester !"A"# $%&'() onto coolant e6pansion tank"

7 Attach cooling system charge unit !AS /+-/ to adapter !"A"# $%&'()"
7 Run 5ent hose $ into a small container %"
2ote
0he 5ented air draws along a small amount of coolant4 which should 9e collected"
7 .lose 9oth 5al5es A and = (turn le5er at right angles to direction of flow)"
7 .onnect hose A to compressed air" l *ressure@ / """ $+ 9ar"

7 8pen 5al5e = 9y setting le5er in direction of flow"
l 0he suction Cet pump generates a partial 5acuum in the cooling systemD the needle on
the gauge should mo5e into the green ;one"
7Also 9riefly open 5al5e A (turn le5er in direction of flow) so that hose on reser5oir
of !AS /+-/ can fill with coolant"
7 .lose 5al5e A again"
7 Lea5e 5al5e = open for another % minutes"
l 0he suction Cet pump continues to generate a partial 5acuum in the cooling systemD the
needle on the gauge should remain in the green ;one"
7 .lose 5al5e ="
l 0he needle on the gauge should stop in the green ;one" 0he 5acuum le5el in the
cooling system is then sufficient for su9sequent filling"

2ote

t 3f the needle does not reach the green ;one4 repeat the process"
t .heck cooling system for leaks if the 5acuum is not maintained"
7 Detach compressed air hose"
7 8pen 5al5e A"
l 0he 5acuum in the cooling system causes the coolant to 9e drawn out of the reser5oir
of !AS /+-/D the cooling system is then filled"
7Detach cooling system charge unit !AS /+-/ from adapter for cooling system tester
!"A"# $%&'() on coolant e6pansion tank" 7 :it pipe for cooling system tester !"A"#
$%&'($+ onto adapter"


7 Remo5e seal arrows"
7 *ull off plenum cham9er co5er $ towards front of 5ehicle"
7 Detach engine co5er panel . 9y remo5ing 9olts arrows"
7*ush 9ack protecti5e slee5e for coolant hoses on connection for heat e6changer"
7 Release coolant hose going to heat e6changer and pull 9ack hose until 9leeder hole in
hose arrow is no longer 9locked 9y connection"
7 :ill up with coolant until it flows out at 9leeder hole in coolant hose"
7 *ush coolant hose 9ack onto connection and secure"
7 8pen 9leeder 5al5e arrow on coolant pipe (rear) 9elow coolant e6pansion tank"
7 :ill up with coolant until it comes out at 9leeder 5al5e"
7 .lose 9leeder 5al5e"

78pen 9leeder 5al5e arrow at coolant pipe (front) 9etween power steering pump and
cylinder head (leftside)"
7 :ill up with coolant until it comes out at 9leeder 5al5e" 7 .lose 9leeder 5al5e"
7 0op up coolant to MAE mark"
78n 5ehicles with au6iliary heater4 switch heater on (for a9out A+ seconds) and then off
again"
7 .lose filler cap on e6pansion tank"
7 Start engine"
7 Set temperature to F,3G"
7 Switch off air conditioner compressor (press E.82 9utton)"
7 Run engine for A minutes at %+++ rpm"
7Allow engine to run at idling speed until two large coolant hoses at radiator 9ecome
warm"
7 Run engine for $ minute at %+++ rpm"
7 Switch off ignition and allow engine to cool down"
7 3nstall noise insulation"
7 .heck coolant le5el"
l 0he coolant le5el must 9e at the MAE marking when the engine is cold"
l 0he coolant le5el can 9e a9o5e the MAE marking when the engine is warm"