Peugeot 308: Draining - filling - bleeding : MHEV hybrid drive train 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
• Bleed pipe
• Compressed air blower
• PH strips
• A collar Rislan

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
	[1512](*)	Pipe clamp
(*) 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. Preliminary operations

Place the vehicle on a lift.

Remove :

• The expansion tank cap
• The under-engine protector
• The front left-hand under-body protector

4. Draining of the MHEV hybrid drive train cooling circuit

ESSENTIAL : The traction battery charge level must be at least 20% of the total charging capacity before initiating the draining/filling/bleeding procedure on the MHEV hybrid drive train cooling circuit : At least 1 line on the traction battery charge level gauge is required.

N.B. : Place a clean tray underneath the engine to collect the coolant from the MHEV hybrid drive train cooling circuit.

CAUTION : Use a receptacle large enough to collect all of the coolant from the hybrid drive train cooling system MHEV.

Uncouple the engine cooling radiator pipe (1).

Detach and move aside :

• The MHEV hybrid drive train cooling circuit pipe (2)
• The MHEV hybrid drive train cooling circuit pipe (3)

Allow the MHEV hybrid drive train cooling circuit coolant to run off.

Connect the hose (1) to the engine cooling radiator .

Drain the MHEV hybrid drive train cooling circuit (Engine cooling radiator side) (At "a" or "d") ; Using an air blower .

Drain the MHEV hybrid drive train cooling circuit (Traction battery side) (At "b" or "c" ; Using an air blower .

N.B. : An additional quantity of fluid runs out.

Allow the MHEV hybrid drive train cooling circuit coolant to run off.

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

5. Filling of the MHEV hybrid drive train cooling circuit

CAUTION : If the MHEV hybrid drive train cooling circuit is contaminated, rinse with clean water.

CAUTION : Always use new coolant.

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

Couple up :

• The MHEV hybrid drive train cooling circuit pipe (2)
• The MHEV hybrid drive train cooling circuit pipe (3)

Position the cooling circuit vacuum filling tool [01102] on the hybrid drive train MHEV cooling circuit expansion tank .

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 MHEV hybrid drive train cooling circuit under a vacuum to reach -0,9 bar (diagram "A").

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

Fill the MHEV hybrid drive train cooling circuit completely and wait for the pressure to return to 0 bar (diagram "B").

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

6. Degassing and check of the MHEV hybrid drive train cooling circuits

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

CAUTION : In the event that the internal combustion engine or the MHEV hybrid drive train cooling circuit electric coolant pumps stop during the degassing procedure, repeat all the operations in the MHEV hybrid drive train cooling circuit degassing procedure.

6.1. Traction battery cooling circuit

Position the tools [0173 / EN-52423], [0173-B / EN-52423] and [0173-C / EN-52423] on the expansion tank filling aperture .

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

Position the tool [1512] on the bleed pipe and close it.

Remove the bleed plug (at "e").

Position :

• A bleed pipe between the filling cylinder [0173 / EN-52423] and the direct voltage transformer (at "e")
• The bleed pipe [0173 / CH-52423-1] in the filling cylinder ; Using a collar Rislan

Pour ‎1 litre of coolant into the filling cylinder and open it.

Remove tool [1512].

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

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
• Follow the instructions on the diagnostic tool
• Access the “engine ECU” menu
• Access the sub-menu / Repair / Repair pack / Service action / Engine engagement
• Activate the traction battery cooling circuit bleed procedure

At the end of the degassing procedure :

• Disconnect the diagnostic tool
• Blank the filling cylinder [0173 / CH-52423-1] using the blocking rod [0173-C / EN-52423]
• Position the tool [1512] on the bleed pipe and close it
• Remove the bleed pipe (at "e")
• Refit the bleed plug (at "e")

N.B. : The level in the expansion tank must be ‎5 mm above the maximum.

6.2. MHEV hybrid drive train cooling circuit

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

Procedure for activating the degassing procedure :

• Start the engine
• Accelerate to an engine speed above 1500 rpm (for 10 seconds) to activate the MHEV hybrid drive train cooling circuit degassing mode
• Maintain the engine speed between 1500 and 2000 rpm : During the degassing procedure

ESSENTIAL : The activation of the fan assembly for a few seconds validates the change to aftersales mode, otherwise the MHEV hybrid drive train cooling circuit degassing procedure should be repeated.

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

Maintain the engine speed between 1500 and 2000 rpm : During the degassing procedure.

N.B. : Once the degassing procedure has been activated, the coolant temperature regulation threshold changes to 80°C, followed by the automatic and permanent activation of the MHEV hybrid drive train cooling circuit electric coolant pumps.

N.B. : The temperature of the coolant continues to rise until it reaches 97°C, then the fan assembly engages in order to lower the temperature to 94°C.

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

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

Switch off the ignition.

Leave the engine to cool.

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

Remove the filling cylinder assembly [0173 / EN-52423] - [0173-B / EN-52423] - [0173-C / EN-52423].

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

Check the coolant fluid level.

7. Additional operations

Refit :

• The expansion tank cap
• The front left-hand under-body protector
• The under-engine protector
• The vehicle to its wheels

N.B. : The coolant level must be checked when cold ; Never open the expansion tank plug when the fluid is hot.

CAUTION : Check that there are no coolant leaks.