Cooling System Repair Procedures

Inspection

1. 1
   Inspect the radiator hoses for the following:

   1. Improper installation
   2. Leaks
   3. Cracks
   4. Damage
   5. Loose connections
   6. Chafing
   7. Deterioration
2. 2
   Check the coolant level in the coolant reservoir. Make sure it is between the "F" and "L" marks.
3. 3
   If the coolant level in the coolant reservoir is at or below the "L" mark, add coolant to a level between the "L" and "F" marks, then inspect the cooling system for leaks.
4. 4
   Remove the radiator cap.
5. 5
   Check for excessive rust or scale deposits around the radiator cap assembly and radiator filler neck. Also, the coolant must not contain oil. If it is excessively contaminated, clean the coolant passage and replace the coolant.
6. 6
   Install the radiator cap.

Coolant Filling and Bleeding

Never remove the reservoir cap while the high-voltage system and electric device radiator are hot. Serious burns may result when hot, pressurized coolant escapes from the reservoir.

When filling electric device coolant, make sure to close the relay box cover and do not allow coolant to contact electrical parts or paint. If coolant spills, wipe it off immediately.

1. 1
   Make sure the electric device system and electric device radiator are cold to the touch.
2. 2
   Remove the reservoir cap (A).

   

3. 3
   Remove the under cover. (Refer to Engine and Transaxle - "Under Cover")
4. 4
   Loosen the drain plug (A) and drain the coolant.

   

5. 5
   Tighten the radiator drain plug securely.
6. 6
   After draining the engine coolant, clean the reservoir tank.
7. 7
   Fill the reservoir with water through the reservoir cap, then tighten the cap.

   For the most effective air bleeding, slowly fill with water and squeeze the upper/lower radiator hoses.

8. 8
   Connect the GDS, then turn on the electric water pump (EWP).

   

   

   

   

9. 9
   Repeat steps 1 through 8 until the drained water is clean.
10. 10
    Slowly fill the 50% coolant and water mixture through the reservoir cap. Squeeze the radiator coolant hoses to bleed air easily.

    Use only genuine antifreeze/coolant. For best corrosion protection, the coolant concentration must be maintained at a minimum of 55% year-round. A coolant concentration below 55% may not provide sufficient corrosion protection or freeze protection. For best corrosion protection, the coolant concentration must be maintained at a minimum of 55% year-round. A coolant concentration below 55% may not provide sufficient corrosion protection or freeze protection. Do not mix antifreezes/coolants of different brands. Do not use additional rust inhibitors or anti-corrosion products; they may be incompatible with the coolant.

11. 11
    Connect the GDS, then turn on the electric water pump (EWP).

    

    

    

    

12. 12
    When the Electric Water Pump (EWP) is running and the electric device coolant is circulating, add electric device coolant through the coolant filler reservoir.
13. 13
    Electric device cooling system bleeding is complete when the electric water pump (EWP) operating noise drops and no air bubbles are visible in the coolant expansion reservoir.

    After bleeding is complete, check that the coolant in the reservoir of the electric device flows without air bubbles when the EWP operates. If the coolant of the electric device does not flow or if air bubbles are still visible, repeat steps 10 through 13.

14. 14
    After bleeding is complete, stop the electric water pump (EWP). Add coolant to the electric device to the "F" level on the electric device reservoir, and install the electric device reservoir cap.

    It takes time to bleed all the air from the cooling system. Add coolant when the coolant has cooled completely, then check the coolant level in the reservoir again 2-3 days after coolant replacement.

    Coolant capacity Without heat pump: approx. 4.1 ~ 4.2 L (1.08 ~ 1.11 U.S. gal, 4.33 ~ 4.44 U.S. qt, 3.61 ~ 3.70 Imp. qt) With heat pump: approx. 4.6 ~ 4.7 L (1.22 ~ 1.24 U.S. gal, 4.86 ~ 4.97 U.S. qt, 4.05 ~ 4.14 Imp. qt)