Cooling system draining
Wait until the engine is cold before starting this procedure. Do not allow antifreeze to come in contact with your skin, or with the painted surfaces of the vehicle. Rinse off spills immediately with plenty of water. Never leave antifreeze lying around in an open container, or in a puddle in the driveway or on the garage floor. Children and pets are attracted by its sweet smell, but antifreeze can be fatal if ingested.
On 1.9 litre DW series engines, release the fasteners from the right-hand side and top of the engine cover then lift off the cover, taking care not to lose its mounting rubbers
. On 2.0 litre engines, release the fixings by turning them through 90°, and remove the engine cover
On 1.9 litre DW series engines, remove the fasteners from the right-hand side...
...and top of the engine cover...
...then remove the cover from the engine
On 2.0 litre engines, release the fixings by turning them through 90°...
...and remove the engine cover
With the engine completely cold, remove the expansion tank filler cap. Turn the cap anti-clockwise until it reaches the first stop. Wait until any pressure remaining in the system is released, then push the cap down, turn it anti-clockwise to the second stop, and lift it off.
Position a suitable container beneath the lower left-hand side of the radiator. On early models, loosen the drain plug (there is no need to remove it completely) and allow the coolant to drain into the container. On later models a drain plug is not provided, so it will be necessary to disconnect the radiator bottom hose to allow the coolant to drain.
To assist draining, open the cooling system bleed screws. These are located in the heater matrix outlet hose union (to improve access, it may be located in an extension hose), on the engine compartment bulkhead and, on 2.0 litre engines, on the top of the thermostat housing
Heater hose bleed screw (arrowed)
Thermostat housing bleed screw (arrowed)
When the flow of coolant stops, reposition the container below the cylinder block drain plug (where fitted). The drain plug is located at the rear of the cylinder block.
Remove the drain plug, and allow the coolant to drain into the container.
If the coolant has been drained for a reason other than renewal, then provided it is clean and less than two years old, it can be re-used, though this is not recommended.
Refit the radiator and cylinder block drain plugs on completion of draining. Also refit the radiator bottom hose (later models) if the system is not to be flushed.
Cooling system flushing
If coolant renewal has been neglected, or if the antifreeze mixture has become diluted, then in time, the cooling system may gradually lose efficiency, as the coolant passages become restricted due to rust, scale deposits, and other sediment. The cooling system efficiency can be restored by flushing the system clean.
The radiator should be flushed independently of the engine, to avoid unnecessary contamination.
To flush the radiator, first tighten the radiator drain plug, and the radiator bleed screw, where applicable.
Disconnect the top and bottom hoses and any other relevant hoses from the radiator.
Insert a garden hose into the radiator top inlet. Direct a flow of clean water through the radiator, and keep flushing until clean water emerges from the radiator bottom outlet.
If after a reasonable period, the water still does not run clear, the radiator can be flushed with a good proprietary cleaning agent. It is important that their manufacturer’s instructions are followed carefully. If the contamination is particularly bad, insert the hose in the radiator bottom outlet, and reverse-flush the radiator.
To flush the engine, first refit the cylinder block drain plug, and tighten the cooling system bleed screws.
Remove the thermostat, then temporarily refit the thermostat cover.
On completion of flushing, refit the thermostat and reconnect the hoses.
With the top and bottom hoses disconnected from the radiator, insert a garden hose into the radiator top hose. Direct a clean flow of water through the engine, and continue flushing until clean water emerges from the radiator bottom hose.
Cooling system filling
Before attempting to fill the cooling system, make sure that all hoses and clips are in good condition, and that the clips are tight. An antifreeze mixture must be used all year round, to prevent corrosion of the engine components (see following sub-Section). Also check that the radiator and cylinder block drain plugs are in place and tight.
| 1.6 litre engines
| 1.8 and 1.9 litre XUD series engnes
| 1.9 litre DW series engines:
| Pre-September 2002 models
| September 2002 models onward
| 2.0 litre engines
||Mixture of monoethylene glycol based antifreeze (PROCOR TM 108, GLYSANTIN G33 or REVKOGEL 2000) and clean de-ionised water
Remove the expansion tank filler cap.
Open all the cooling system bleed screws (see paragraph 4).
Some of the cooling system hoses are positioned at a higher level than the top of the radiator expansion tank. It is therefore necessary to use a ‘header tank’ when refilling the cooling system, to reduce the possibility of air being trapped in the system. Although Peugeot/Citroën dealers use a special header tank, the same effect can be achieved by using a suitable bottle, with a seal between the bottle and the expansion tank
(see Haynes Hint)
Cut the bottom off an old antifreeze container to make a ‘header tank’ for use when refilling the cooling system. The seal at the point arrowed should be as airtight as possible – use an O-ring if available, or seal the joint by some other means.
Fit the ‘header tank’ to the expansion tank and slowly fill the system. Coolant will emerge from each of the bleed screws in turn, starting with the lowest screw. As soon as coolant free from air bubbles emerges from the lowest screw, tighten that screw and, where applicable, watch the next bleed screw in the system. Repeat the procedure until the coolant is emerging from the highest bleed screw in the cooling system and all bleed screws are securely tightened.
Continue to fill the cooling system until bubbles stop appearing in the expansion tank. Help to bleed the air from the system by repeatedly squeezing the radiator bottom hose.
Ensure that the ‘header tank’ is full (at least 0.5 litres of coolant). Start the engine, and run it at a fast idle speed (do not exceed 2000 rpm) until the cooling fan cuts in, and then cuts out. Stop the engine. Note: Take great care not to scald yourself with the hot coolant during this operation.
Allow the engine to cool, then remove the ‘header tank’.
When the engine has cooled, check the coolant level. Top-up the level if necessary, and refit the expansion tank cap. Refit the engine cover (where applicable).
The antifreeze should always be renewed at the specified intervals. This is necessary not only to maintain the antifreeze properties, but also to prevent corrosion which would otherwise occur as the corrosion inhibitors become progressively less effective.
Always use an ethylene-glycol based antifreeze of the specified type.
Before adding antifreeze, the cooling system should be completely drained, preferably flushed, and all hoses checked for condition and security.
After filling with antifreeze, a label should be attached to the expansion tank, stating the type and concentration of antifreeze used, and the date installed. Any subsequent topping-up should be made with the same type and concentration of antifreeze.
Do not use engine antifreeze in the windscreen/tailgate washer system, as it will cause damage to the vehicle paintwork. A screenwash additive should be added to the washer system in the quantities stated on the bottle.