Peugeot 308: Draining - filling - bleeding : Traction battery cooling circuit

ESSENTIAL : Observe the safety and cleanliness recommendations .

CAUTION : Refer to the vehicle’s servicing schedule for the coolant checking interval.

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

1. Tooling

Workshop equipment : Diagnostic tool.

Tool	Reference	Description
	[01102]	Tool for filling the cooling system by vacuum
	[0173][EN-52423]	Bayonet filling cylinder
	[0173-B][EN-52423]	Adaptor / extension for bayonet filling cylinder
	[0173-C][EN-52423]	blocking rod for filling cylinder

2. Checking the coolant fluid

Check the pH of the coolant ; Using reactive strips.

N.B. : The pH value of the coolant should be between 6,3 and 8.

Replace the coolant if the pH value is out of tolerance.

3. Preliminary operations

Place the vehicle on a 2-post lift.

Open the charging flap.

Unclip the charging socket unit trim (1) (at "a") ; Using an Allen key.

Remove :

• The expansion tank cap (Carefully)
• The rear under-body protectors (right-hand side)
• The rear left-hand wheel

4. Draining of the traction battery cooling circuit

Remove the bolts (2).

Move aside the rear exhaust silencer (3).

Remove :

• The 5 bolts (7)
• The protection shield (6)
• The bolt (5)
• The nuts (4), (8)
• The exhaust heat shield (9)

N.B. : Place a clean container under the traction battery cooling circuit pipe to collect the coolant.

Unclip the clip (at "b").

Uncouple the traction battery cooling circuit pipe (10).

Unclip the clip (at "c").

Uncouple the traction battery cooling circuit pipe (11).

Allow the coolant to drain out of the traction battery .

CAUTION : If the tool for filling the cooling system by vacuum [01102] is used, measure the quantity of coolant drained.

Unclip (at "d").

Uncouple the traction battery cooling circuit pipes (11), (12).

Drain the traction battery ; Using an air blower (at "e").

Drain the traction battery cooling circuit (at "f" and "g") ; Using an air blower .

5. Filling of the traction battery cooling circuit

CAUTION : If the traction battery cooling circuit is contaminated, rinse with clean water.

CAUTION : Always use new coolant.

CAUTION : Each filling operation must always be followed by a hybrid drive train cooling circuit degas operation.

Couple the traction battery cooling circuit pipes (10), (11).

Reclip (at "b", "c").

Couple the traction battery cooling circuit pipes (11), (12).

Reclip (at "d").

Position the cooling circuit vacuum filling tool [01102] on the traction battery cooling circuit expansion chamber .

Refit :

• The exhaust heat shield (9)
• The nuts (4), (8)
• The bolt (5)
• The protection shield (6)
• The 5 bolts (7)
• The exhaust rear silencer (3)
• The bolts (2)

CAUTION : To avoid entry of air into the circuit, allow for 20% of additional coolant.

Prepare a receptacle of coolant containing the quantity of fluid drained + 20 %.

N.B. : The receptacle must be positioned slightly lower than the equipment for filling by vacuum.

Place the traction battery cooling circuit under a vacuum to reach -0,9 bar (diagram "A").

Wait 10 seconds and check that the value obtained does not drop.

Completely fill the traction battery cooling circuit and wait for the pressure to return to 0 bar (diagram "B").

N.B. : The quantity of coolant filled should correspond to the quantity of fluid drained.

CAUTION : Remove the equipment for filling by vacuum [01102] and rinse the assembly with clean water.

6. Degassing and check of the traction battery cooling circuit

ESSENTIAL : The air conditioning control should not operate during this phase.

CAUTION : If the traction battery cooling circuit electric coolant pump stops during the degas procedure, repeat all the operations for the traction battery cooling circuit degas procedure.

ESSENTIAL : Place a charger on one of the ancillaries batteries to prevent it from discharging.

Fitting with filling cylinder offset ; Using the tools [0173-B / EN-52423], [0173-C / EN-52423], [0173 / EN-52423].

Position the tools [0173 / EN-52423], [0173-B / EN-52423], [0173-C / EN-52423] on the traction battery cooling circuit expansion chamber (according to assembly).

Open the rod [0173-C / EN-52423] on the filling cylinder [0173 / EN-52423].

Slowly fill the filling cylinder [0173 / EN-52423] with clean coolant.

ESSENTIAL : Bleeding of the traction battery cooling circuit must be carried out with the diagnostic tool. The diagnostic tool allows the traction battery cooling circuit electric coolant pump to be activated.

CAUTION : Observe the order of the operations below.

Traction battery cooling circuit degas procedure :

• Connect the diagnostic tool
• Access the ECU:On-board charger/direct voltage transformer assembly
• Access the sub-menu / Repair / Repair pack / Service action
• Activate the traction battery cooling circuit bleed procedure

N.B. : The procedure ends after the traction battery cooling circuit electric coolant pump has been rotating for 60 minutes.

Disconnect the diagnostic tool.

CAUTION : After completing the degas procedure, check that there are no traction battery coolant leaks.

Blank the filling cylinder [0173 / EN-52423] using the blocking rod [0173-C / EN-52423].

Remove the tools [0173 / EN-52423], [0173-B / EN-52423], [0173-C / EN-52423].

Check the coolant fluid level.

Top up the coolant to the "max" level.

CAUTION : Do not fill the expansion chamber beyond the maximum mark.

7. Additional operations

Refit :

• The rear under-body protectors (right-hand side)
• The rear left-hand wheel
• The expansion tank cap
• The charging socket unit trim (1)
• The vehicle to its wheels

Close the charging flap.