Service Procedure
A. Inspect Coolant Reservoir Outlet Hose Dimension1. Open the hood.
2. Locate the coolant reservoir outlet hose (Figure 1).
3. Measure the distance from the end of the coolant reservoir outlet hose to the coolant reservoir (bottle) (Figure 2):
< If the distance is 0.275 in. (7mm) or less, no further action is required. Close the hood and return the vehicle to the customer.
< If the distance is greater than 0.275 in. (7mm), continue with Section B. Adjust Coolant Reservoir Outlet Hose.
B. Adjust Coolant Reservoir Outlet Hose
1. Use the following procedure to remove the radiator cap:
< On a cold engine, slowly rotate the radiator cap counterclockwise until the radiator cap reaches the first stop (Figure 3). Then push down and rotate the radiator cap counterclockwise to remove the cap completely.
< On a hot engine, if the engine has been run recently, wait 15 minutes before removing the radiator cap. Then place a shop towel over the radiator cap and without pushing down slowly rotate the radiator cap counterclockwise to the first stop (Figure 3). Allow system pressure to escape through the overflow hose. After the system pressure has been released, push down and rotate the radiator cap counterclockwise to remove the cap completely.
2. Remove the air cleaner retaining screw at the radiator core support (Figure 3).
3. Loosen the air cleaner outlet hose clamp at the air cleaner assembly and separate the air cleaner outlet hose from the air cleaner assembly (Figure 3).
4. Remove the air cleaner assembly to gain access to the coolant reservoir outlet hose clamp (Figure 3).
5. Release the coolant reservoir outlet hose clamp using hose clamp pliers and position the hose as far forward (in car position) as it will go on the coolant reservoir outlet nipple (Figure 4).
6. Measure the distance from the end of the coolant reservoir outlet hose to the coolant reservoir (bottle) (Figure 2):
< If the distance is 0.275 in. (7mm) or less, continue to Step 7.
< If the distance is greater than 0.275 in. (7mm), continue with Section C. Replace Coolant Reservoir Outlet Hose.
7. Clean the filler neck sealing surface of the coolant reservoir (bottle).
8. Check the coolant level in the coolant reservoir (bottle) and add coolant if required.
NOTE:
Coolant being added must be premixed 50% water/50% coolant.
9. Install the radiator cap onto the coolant reservoir (bottle) filler neck (Figure 3).
10. Install the air cleaner assembly (Figure 3).
11. Install the air cleaner assembly retainer screw at the radiator core support (Figure 3).
12. Install the air cleaner outlet hose to the air cleaner assembly and tighten the air cleaner outlet hose clamp (Figure 3).
13. Close the hood and return the vehicle to the customer.
C. Replace Coolant Reservoir Outlet Hose
1. Drain and save one gallon of coolant from the radiator into a clean container.
2. Remove the coolant reservoir outlet hose (Figure 1).
3. Transfer the protective sleeve and rear hose clamp (in car position) from the old coolant reservoir outlet hose to the new coolant reservoir outlet hose (Figure 2).
4. Install the new coolant reservoir outlet hose by positioning the end of the hose with the glued on clamp as far forward (in car position) as it will go on the coolant reservoir outlet nipple. Then install the rear section of the coolant reservoir outlet hose until it makes contact with the aluminum heater tube stop bead.
5. Open the bleeder screw on the thermostat housing (Figure 5).
6. Clean the filler neck sealing surface of the coolant reservoir (bottle) (Figure 3).
7. Fill the cooling system with the coolant that was removed in Step 1.
8. Once coolant begins to drip from the thermostat housing bleeder screw, close the bleeder screw (Figure 5).
9. Check the coolant level in the coolant reservoir (bottle) and add additional coolant if required.
NOTE:
Coolant being added must be premixed 50% water/50% coolant.
10. Install the radiator cap onto the coolant reservoir (bottle) filler neck (Figure 3).
11. Install the air cleaner assembly (Figure 3).
12. Install the air cleaner assembly retainer screw at the radiator core support (Figure 3).
13. Install the air cleaner hose to the air cleaner assembly and tighten the air cleaner hose clamp (Figure 3).
14. Rinse any residual coolant from the engine and belly pan as necessary.
15. Close the hood and return the vehicle to the customer.