Instructions For Working On Cooling System.
Warning: Danger of scalding! Work on the cooling system should only be carried out when the engine has cooled down.
- When working on the oil, coolant or fuel circuit, you must protect the alternator against contamination.
- Cover alternator with suitable materials.
- Failure to comply with this procedure may result in an alternator malfunction.
- Open cooling system only when it has cooled down.
- Opening the cooling system while hot can result in air entering the system.
- This can cause overheating with permanent damage to the engine.
Catch and dispose of drained coolant.
Observe country specific waste disposal regulations.
Coolant System Drain and Refill
- Remove pressure cap.
- Remove lower hose from radiator, and heater hoses at bulkhead. Use caution when coolant is hot.
- Reinstall hoses after coolant has drained.
- Open the coolant bleed screws in the upper hose and the heater return hose (protect generator).
- Fill engine with coolant (50/50 mix) through thermostat housing (expansion tank in COOPER S).
- Continue to fill through thermostat housing (or expansion tank).
- Fill expansion tank to "MAX".
- Start engine and run at idle. Top up coolant as necessary.
- Turn off engine and install pressure cap.
Removing And Installing/replacing Coolant Thermostat (COOPER S)
Warning: Danger of scalding!
Work on the cooling system should only be carried out when the engine has cooled down.
Remove coolant pressure cap from expansion tank.
Remove intake filter housing.
Remove MAP sensor connector
Remove MAP sensor bracket bolts
Remove heater hose
Remove top hose from thermostat housing.
Remove retaining bolt and remove thermostat housing
NOTE THE LOCATION OF THE BLEEDING PIN AND THE DIRECTION THE THERMOSTAT GOES IN, BEFORE YOU REMOVE IT.