Section 03
ENGINE
Subsection 05
(COOLING SYSTEM)
03-05-4
VMR2004_009_03_05A.FM
COOLING SYSTEM REFILLING
Recommended Coolant
Use a blend of 50% antifreeze with 50% water.
CAUTION:
To prevent rust formation or freezing
condition, always replenish the system with 50%
antifreeze and 50% water. Pure antifreeze without
water freezes. Always use ethylene-glycol anti-
freeze containing corrosion inhibitors specifically
recommended for aluminum engines.
System Capacity
Refer to TECHNICAL DATA.
Refilling Procedure
With vehicle on a flat surface, engine cold, remove
the temperature sensor
no. 7
on the top of ther-
mostat housing. Fill radiator
no. 8
until coolant get
out by the temperature sensor hole. Install the
temperature sensor and continue the cooling sys-
tem filling by the radiator. Fill coolant tank
no. 9
up
to cold level mark. Install radiator pressure cap.
Run engine for brief period then stop engine. Refill
up to mark, if necessary.
When engine has completely cooled down, re-
check coolant level in radiator
no. 8
and coolant
tank
no. 9
and top up if necessary.
Check coolant concentration (freezing point) with
proper tester.
PRESSURE CAP
Check if radiator pressure cap
no. 1
pressurizes
the system. If not, install a new 110 kPa (16 PSI)
radiator pressure cap (
do not exceed this pres-
sure
).
WATER PUMP
Removal
Drain coolant.
Remove water pump cover
no. 6
from water
pump with O-ring
no. 10
.
Drive out spring pin
no. 11
and remove impeller
no. 12
.
Remove left engine housing cover.
Remove shaft
no. 13
by pulling inwards.
Remove thrust washer
no. 14
, needle pin
no. 15
and gear
no. 16
.
Press out sealing rings
no. 3
and
no. 4
.
Inspection
Check shaft
no. 13
for traces of sealing rings and
replace if necessary.
Check if the O-ring
no. 10
in water pump cover is
brittle, hard or otherwise damaged.
Installation
For installation, reverse the removal procedure.
NOTE:
Do not drive spring pin into impeller until
engine housing cover has been installed.
Drive internal sealing ring
no. 4
firmly into place.
Fill cavity between sealing rings with Molykote 111
paste.
Drive external sealing ring
no. 3
into place with the
relevant adapter until flush with the race.
RADIATOR
Removal
Drain cooling system.
Remove:
– front facia (refer to BODY)
– inlet
no. 17
and outlet
no. 18
hoses
1. Radiator inlet hose
2. Radiator outlet hose
1
V02C11A
2
Summary of Contents for DS 650
Page 1: ......
Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
