Special Tools

J 38185 Hose Clamp Pliers

Warning: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Remove the left headlamp. Refer to Headlamp Replacement
2. Remove the front bumper fascia air deflector. Refer to Front Bumper Fascia Air Deflector Replacement
3. Place a drain pan under the left front corner of the vehicle.



4. Remove the air separator bolt (3) from the vehicle.
5. Reposition the surge tank outlet hose clamp (1).
6. Reposition the surge tank outlet hose (2) and air separator toward the center of the vehicle to provide a direct coolant drain path.
7. Remove the surge tank outlet hose from the air separator.
8. Drain the coolant.

Caution: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

Note: Use pre-mixed DEX-COOL only. Pre-mix DEX-COOL contains the proper 50/50 mixture of DEXCOOL and de-ionized water necessary to prevent corrosion damage to the generator control module internal heat sink. Never use tap water in the hybrid cooling system.

1. Install the surge tank outlet hose to the air separator.
2. Reposition the surge tank outlet hose clamp on the air separator.
3. Install the air separator bolt to the vehicle and tighten to 9 N·m (80 lb in).

Note: Use pre-mixed DEX-COOL only. Pre-mix DEX-COOL contains the proper 50/50 mixture of DEXCOOL and de-ionized water necessary to prevent corrosion damage to the generator control module internal heat sink. Never use tap water in the hybrid cooling system.

4. Remove the right headlamp. Refer to Headlamp Replacement



5. Reposition the hybrid radiator inlet hose clamp (1).
6. Remove the hybrid radiator inlet hose from the hybrid radiator (2).
7. Using a clean flexible funnel or similar tool, slowly fill the hybrid radiator with the pre-mixed DEX-COOL and de-ionized water. Refer to Approximate Fluid Capacities



8. With the hybrid radiator inlet hose positioned upward, slowly add the pre-mixed DEX-COOL and de-ionized water to the surge tank (1) until coolant is visible in the hybrid radiator inlet hose.
9. Install the hybrid radiator inlet hose to the hybrid radiator.
10. Reposition the hybrid radiator inlet hose clamp.
11. Turn the ignition ON.
12. As the cooling pumps run, air will purge into the surge tank and the coolant level will drop. Top off the coolant as necessary until the coolant is maintained at the Cold Full line.
13. Install the coolant pressure cap.