Drain and refill - ’d’ series (Cooling system)

DRAIN AND REFILL - ’D’ SERIES

Service repair no - 26.10.01

Drain

1. Visually check engine and cooling system for signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion and security of connections.
3. Turn heater temperature control to maximum heat position.
4. Remove radiator filler cap.
5. Position drain tin to collect coolant.

6. Loosen radiator drain plug, remove cylinder block drain plug .
7. Allow cooling system to drain.
8. Remove expansion tank from its bracket drain coolant and return to bracket.

Refill

1. Flush system with water under low pressure.

CAUTION: High pressure water could damage the radiator.

2. Clean and apply Loctite 577 sealant to drain plug thread. Fit plug with a NEW washer and tighten to 80 Nm.
3. Tighten radiator drain plug.
4. Ensure heater temperature control is set at maximum heat position.
5. Prepare coolant to required concentration, See INFORMATION, Capacities, fluids and lubricants. .

6. Up to 97.5MY: Loosen bleed screw on top coolant hose adaptor.
7. Fill expansion tank to ’MAX’ mark.
8. Fill cooling system until coolant level reaches base of filler neck. Up to 97.5MY: When coolant flows from the bleed screw, tighten screw to 10 Nm,
9. Fit radiator cap and tighten only to first stop.
10. Start and run engine until radiator cooling fan operates at least twice.
11. Switch off engine, check level in radiator and add coolant if needed. Refit radiator cap and tighten fully.
12. Add coolant to expansion tank ’MAX’ mark and fit cap.
13. Check cooling system for leaks.