Peugeot 308: Draining - filling - bleeding : Engine cooling circuit

ESSENTIAL : Observe the safety and cleanliness recommendations .

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

1. Tooling

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]
	[0173-C][EN-52423]	blocking rod for filling cylinder
	[0173-2] (*)	Screw-fit filling cylinder (without extension)
	[0165-2][GE-47622]	Cable pliers for flexible clamps
(*) Use standard workshop equipment if the special tool is not available

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. Draining of the engine cooling system

ESSENTIAL : The draining operation is carried out with the engine cold.

Put the vehicle on a lift .

Remove :

• The under-engine protector (depending on equipment)
• The expansion tank cap (Carefully)

N.B. : Place a clean container underneath the engine to recover the engine coolant.

Uncouple the pipe (1)(at "a") ; Using the tool [0165-2 / GE-47622].

Allow the coolant to run out.

Drain the cylinder block(if necessary).

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

4. Filling of the engine cooling circuit

CAUTION : If the engine cooling system is contaminated, rinse with clean water.

CAUTION : Always use new coolant.

CAUTION : Each filling operation must always be followed by an engine cooling circuit degassing operation.

4.1. Filling the cooling system by gravity

Couple the pipe (1)(at "a") ; Using the tool [0165-2 / GE-47622].

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

"B" : Fitting with filling cylinder direct ; Using the tool [0173-2].

Fit the filling cylinder , blank and adaptor assembly on the expansion chamber(according to assembly).

Open the cap on the filling cylinder .

Open the bleed screws located on the coolant outlet housing and the heater pipe.

Slowly fill the cooling system with clean coolant.

Close the bleed screw when the fluid is flowing freely without any air bubbles.

N.B. : The filling cylinder must be filled to the 1 litre mark to bleed the heater matrix correctly.

4.2. Filling using the tool for filling the cooling system by vacuum

CAUTION : Always use new coolant.

Couple the pipe (1)(at "a") ; Using the tool [0165-2 / GE-47622].

Close the bleed screw .

Put the equipment for filling by vacuum [01102] in place on the expansion bottle .

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 cooling circuit under a vacuum to reach -0,9 bar(diagram "C").

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

Fill the cooling circuit completely and wait for the return to 0 bar(diagram "D").

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

Repeat the operation until the cooling system is full(if necessary).

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

5. Degassing and checking the cooling system

Fit the charging cylinder , closer and adaptor assembly on the expansion bottle, in the case of draining using the tool for filling by vacuum [01102].

Open the cap on the filling cylinder .

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

CAUTION : If the engine stops during the degassing procedure, repeat all the operations of the engine cooling system degassing procedure.

5.1. All engines - DW10FU, DW12RU Diesel engines (Except diesel engines DW10F, DV6F and DV5R)

CAUTION : Observe the order of the operations below.

To degas the engine cooling system :

• Start the engine
• Accelerate to an engine speed of 1500 - 2000 rpm for 10 seconds to be sure of priming the alternator
• Keep the engine speed at 1500 - 2000 rpm for approximately 20 minutes

N.B. : The procedure ends after 2 triggering cycles and after the fan assembly has stopped.

CAUTION : Check to confirm that there are no engine coolant leaks after the degassing procedure.

5.2. Engines DW10F and DV6F (Except DW10FU engine)

CAUTION : Bleeding the cooling circuit of Diesel engines with EURO 6 emissions control standard must be carried out with the assistance of the diagnostic tool. The diagnostic tool checks the correct positioning of the bleed valve and guides the operator step-by-step during the bleeding operation.

CAUTION : Observe the order of the operations below.

To degas the engine cooling system :

• Connect the diagnostic tool
• Access the sub-menu : " Degassing of the engine cooling circuit "
• Start the engine
• Accelerate to an engine speed above 2300 rpm for more than 10 seconds to switch to degas mode. The fan assembly is triggered for 10 seconds
• Check the switch to degas mode by checking the cutting in of the fan assembly for 10 seconds
• Keep the engine speed at 2500 rpm for approximately 20 minutes

N.B. : The procedure ends after a triggering cycle and after the fan assembly has stopped.

Disconnect the diagnostic tool.

CAUTION : Check to confirm that there are no engine coolant leaks after the degassing procedure.

5.3. DV5R Diesel engines

CAUTION : Bleeding the cooling circuit of the DV5R engine must be carried out with the diagnostic tool. The diagnostic tool checks that the system has switched to degas mode and guides the operator step-by-step during the bleeding process.

CAUTION : Observe the order of the operations below.

To degas the engine cooling system :

• Connect the diagnostic tool
• Access the sub-menu : " Degassing of the engine cooling circuit "
• Start the engine
• Accelerate to an engine speed above 2300 rpm for 10 seconds to switch to degas mode
• Keep the engine speed at 2500 rpm for approximately 20 minutes

N.B. : The procedure ends after 2 triggering cycles and after the fan assembly has stopped.

Disconnect the diagnostic tool.

CAUTION : Check to confirm that there are no engine coolant leaks after the degassing procedure.

5.4. Degassing and checking the cooling system(continued)

CAUTION : Check that the level of coolant in the filling cylinder is sufficient.

Switch off the engine.

CAUTION : Do not remove the filling cylinder while the engine is hot.

Leave the engine to cool.

Blank the filling cylinder using the blocking rod .

Remove the filling cylinder , plug and adapter assembly.

Check the coolant level when cold.

Top up the coolant to the "max" level (Cold).

CAUTION : Do not fill the system past the max mark.

Fit and tighten the plug on the expansion tank .

CAUTION : Check that the cooling system filler cap is locked (For bayonet cap).

Refit :

• The under-engine protector (depending on equipment)
• The vehicle to its wheels