Coolant Reservoir: Service and Repair

Coolant Expansion Tank

Service Repair No - 26.15.01

Removal

WARNING: Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn. Cover the expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure to follow this instruction may result in personal injury.

CAUTION: Engine coolant will damage the paint finished surfaces. If spilt, immediately remove the coolant and clean the area with water.

1. Disconnect the battery ground cable.
2. Remove the coolant expansion tank cap.

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.





3. Disconnect the 2 hoses from the coolant expansion tank.
^ Clamp the hoses
^ Release the 2 clips.





4. Disconnect the coolant low level sensor electrical connector.





5. NOTE: Do not disassemble further if the component is removed for access only.

Remove the coolant expansion tank.
^ Remove the 2 bolts.
^ Release from the clip.





Installation

1. NOTE: Install a new coolant low level sensor if not part of the new coolant expansion tank assembly.

Install the coolant expansion tank.
^ Secure with the clip.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).

2. Connect the coolant low level sensor electrical connector.
3. Connect the expansion tank coolant hoses.
^ Secure with the clips.
^ Remove the hose clamps.

4. Top-up the coolant.
^ Fill with coolant to approximately 30mm ABOVE the maximum cold fill line.
5. Connect the battery ground cable.
6. Bleed the air from the cooling system.
^ Make sure that the expansion tank cap is removed.
^ Connect exhaust extraction hoses to the tail pipes.
^ Start and run the engine.
^ Hold the engine at 3000 rpm for 1 minute.
^ Return the engine to idle for five minutes.
^ Hold the engine at 3000 rpm for 1 minute.
^ Make sure that the coolant level is maintained to approximately 30mm ABOVE maximum cold fill line during the bleed procedure (with the expansion tank cap removed).

7. Check all coolant hoses for visible signs of coolant leaks.
8. Install the expansion tank cap after making sure that the final coolant level is 30mm above the maximum cold fill line.