‹

Coolant Reservoir

Engine, Cooling and Exhaust › Cooling System
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartReservoir Cap
ManufacturerCHY
OEM part #68020726AB
Price$16.10
PartReservoir
ManufacturerCHY
OEM part #68024572AB
Price$259.00

Labor

Replace — Expansion Tank0.4 hr
Warranty 0.0 hrSkill C
Procedures
Coolant Recovery Bottle - Installation — Non-Pressure System4 steps
Fig. 1
Fig. 1
  1. Position coolant recovery container (1).
  2. Install the fasteners across the upper support and the outside lower edges of the reservoir (1 each side).
  3. Install two washer pump hoses, coolant recovery hose and washer pump electrical connector from the combination coolant recovery/washer fluid reservoir assembly (1).
  4. Connect negative battery cable.
Coolant Recovery Bottle - Installation — Pressure System5 steps
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  1. Position pressure bottle on mounting bracket.
  2. Install mounting nuts. Tighten nuts to 8.5 Nm (75 in. lbs.).
  3. Install lower hose at coolant bottle.
  4. Install radiator to coolant bottle hose at coolant bottle.
  5. Fill cooling system Service and Repair.
Coolant Recovery Bottle - Removal — Non-Pressure System4 steps
Fig. 1
Fig. 1
  1. Disconnect negative battery cable.
  2. Disconnect two washer pump hoses, coolant recovery hose and washer pump electrical connector from the combination coolant recovery/washer fluid reservoir assembly (1).
  3. Remove the fasteners across the upper support and on the lower edges of the reservoir (1 each side).
  4. Remove the combination coolant recovery/washer fluid reservoir assembly (1).
Coolant Recovery Bottle - Removal — Pressure System6 steps
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  1. Remove pressure cap from bottle.
  2. Siphon coolant from pressure bottle (2) into a contaminant free container.
  3. Disconnect coolant bottle to radiator hose at coolant bottle.
  4. Disconnect lower hose at coolant bottle.
  5. Remove mounting nuts.
  6. Remove coolant bottle from bracket.
Description - Pressure Systemreference
PRESSURE SYSTEM This system works on the principal of a closed and deaerated system using thermally generated pressure. The expansion and contraction of the coolant in the pressurized closed system keeps it free of trapped air. It provides: -A pressurized surge tank volume for expansion and contraction. -A non-pressurized overflow volume to capture excess coolant expansion and allow for it's return to the pressurized system. -A pressurized cap on the pressure bottle rather than the radiator. This facilitates deaeration of the system. -Reserve coolant is included in the pressurized volume to account for minor leaks and evaporation or boiling losses. -Provides a warning light for low coolant level.
Description - Non-Pressure Systemreference
NON-PRESSURE SYSTEM This system works on the principal of a closed and completely deaerated system using thermally generated pressure. The bottle acts as a reserve coolant source to keep air out of the system but must have a specified minimum amount of coolant in the bottle at all times. The expansion and contraction of the coolant in the pressurized closed coolant loop allows the reserve bottle to accept and give up excess fluid via a hose from the radiator neck. It provides: -A non-pressurized reserve coolant tank volume for expansion and contraction of coolant. -A pressurized cap on the radiator. This keeps the main loop of the cooling system at an elevated operating pressure and prevents coolant boiling at lower temperatures. -Reserve coolant is included in the non-pressurized tank in enough quantity to account for minor leaks and evaporation or boiling losses, and to keep the return line back to the radiator full at all times. Failure to do so could allow air to be sucked back into the radiator as the engine and engine coolant cool down and the coolant volume contracts.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
DESCRIPTION-NON-PRESSURE SYSTEM
This system works on the principal of a closed and completely deaerated system using thermally generated pressure. The bottle acts as a reserve coolant source to keep air out of the system but must have a specified minimum amount of coolant in the bottle at all times. The expansion and contraction of the coolant in the pressurized closed coolant loop allows the reserve bottle to accept and give up excess fluid via a hose from the radiator neck. It provides:
A non-pressurized reserve coolant tank volume for expansion and contraction of coolant. A pressurized cap on the radiator. This keeps the main loop of the cooling system at an elevated operating pressure and prevents coolant boiling at lower temperatures. Reserve coolant is included in the non-pressurized tank in enough quantity to account for minor leaks and evaporation or boiling losses, and to keep the return line back to the radiator full at all times. Failure to do so could allow air to be sucked back into the radiator as the engine and engine coolant cool down and the coolant volume contracts.
DESCRIPTION-PRESSURE SYSTEM
This system works on the principal of a closed and deaerated system using thermally generated pressure. The expansion and contraction of the coolant in the pressurized closed system keeps it free of trapped air. It provides:
A pressurized surge tank volume for expansion and contraction. A non-pressurized overflow volume to capture excess coolant expansion and allow for it's return to the pressurized system. A pressurized cap on the pressure bottle rather than the radiator. This facilitates deaeration of the system. Reserve coolant is included in the pressurized volume to account for minor leaks and evaporation or boiling losses. Provides a warning light for low coolant level.
OPERATION-NON PRESSURE SYSTEM
The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses.
As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator.
OPERATION-PRESSURE SYSTEM
As the engine warms, the coolant in the closed system expands. The pressurized bottle accepts the expanding fluid. Then, when the thermostat opens and a high demand for coolant is placed on the system, the pressurized surge tank side of the bottle can supply the temporary additional volume of coolant demanded by the system. Once the water pump catches up with the flow demand, the tank returns to equilibrium. A separate compartment in the bottle accepts the overflow coolant which is then drawn back into the primary side of the bottle when the engine and coolant cool down
The advantage of the pressurized system is that any excess air in the cooling system is routed to the top of the bottle via a vent hose at the thermostat housing to the bottle. This air accumulates at the top of the pressurized volume in the bottle (the highest point in the system) and is forced out of the system through the pressure cap. This keeps the system properly deaerated and maintains pressure in the cooling system to prevent water pump cavitation
The diesel bottle has an additional vent line back to the radiator that is immersed in the coolant bath at the bottle. This also ensures air at the radiator is routed back to bottle for expulsion and that a constant head of liquid is present at the radiator.
REMOVAL-NON PRESSURE SYSTEM
1 - RADIATOR PRESSURE CAP 2 - HOSE 3 - COOLANT RECOVERY BOTTLE
1. Remove hose (2) from radiator. 2. Remove recovery container mounting bolts. 3. Remove recovery container (3).
REMOVAL-PRESSURE SYSTEM📷 2
1 - PRESSURE CAP 2 - COOLANT BOTTLE 3 - MOUNTING NUTS 4 - COOLANT BOTTLE TO RADIATOR HOSE 5 - CLAMP 6 - RADIATOR 7 - LOWER HOSE 8 - MOUNTING BRACKET
1. Remove pressure cap from bottle. 2. Siphon coolant from pressure bottle (2) into a contaminant free container. 3. Disconnect coolant bottle to radiator hose at coolant bottle.
4. Disconnect lower hose at coolant bottle. 5. Remove mounting nuts. 6. Remove coolant bottle from bracket.
figure
figure
INSTALLATION-NON PRESSURE SYSTEM📷 1
1 - RADIATOR PRESSURE CAP 2 - HOSE 3 - COOLANT RECOVERY BOTTLE
1. Position coolant recovery container (3). 2. Install coolant recovery container mounting bolts.
3. Install hose (2).
figure
INSTALLATION-PRESSURE SYSTEM📷 1
1 - PRESSURE CAP 2 - COOLANT BOTTLE 3 - MOUNTING NUTS 4 - COOLANT BOTTLE TO RADIATOR HOSE 5 - CLAMP 6 - RADIATOR 7 - LOWER HOSE 8 - MOUNTING BRACKET
  1.   Position pressure bottle on mounting bracket.
  2.   Install mounting nuts. Tighten nuts to 8.5 N.m (75 in. lbs.).
  3.   Install lower hose at coolant bottle.
  4.   Install radiator to coolant bottle hose at coolant bottle.
  5.   Fill cooling system. See STANDARD PROCEDURE.
figure