1、 WORLDWIDE ENGINEERING STANDARDS Test Procedure GMW14905 Service Coolant Fill Procedure Copyright 2011 General Motors Company All Rights Reserved December 2011 Originating Department: North American Engineering Standards Page 1 of 6 1 Scope Note: Nothing in this standard supercedes applicable laws a
2、nd regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. To ensure that service fill operations will result in a properly filled system when it leaves the dealership without thermal cycling. This procedure will
3、 determine the quantity of coolant that must be added after the filling procedure. 1.2 Foreword. Not applicable. 1.3 Applicability. Not applicable. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Stan
4、dards/Specifications. None 2.3 Additional References. Architecture Technical Specification (ATS) Engine Subsystem Technical Specification (SSTS) or other engine requirement document Vehicle Service Manual Vehicle Technical Specification (VTS) 3 Resources 3.1 Facilities. Any facility with a flat surf
5、ace and ambient temperature not below (20 5) C. 3.2 Equipment. 500 mL beaker, stopwatch, thermocouple, vent valves, external cooling fan, tachometer or other means of measuring the engine rpm. 3.3 Test Vehicle/Test Piece. Test vehicle including all cooling system assembly design intent routing, hard
6、ware, and engine. 3.4 Test Time. Calendar time: 3 days Test hours: 6 hours to 8 hours Coordination hours: 3 hours to 4 hours 3.5 Test Required Information. Release drawing of cooling system assembly. 3.6 Personnel/Skills. Not applicable. 4 Procedure 4.1 Preparation. Copyright General Motors Company
7、Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14905 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 2 of 6 4.1.1 Install a sight glass in t
8、he upper radiator hose. The influence of the sight glass on the hose routing and the flow distribution must be minimized. 4.1.1.1 An additional sight glass may be installed in the heater return hose. The influence of the sight glass on the hose routing and the flow distribution must be minimized. 4.
9、1.2 Install a thermocouple stinger in the lower radiator hose. Also, it is optional to install a thermocouple stinger in the upper radiator hose. 4.1.2.1 A “HOKE“ shutoff valve may be installed if the radiator does not have a draincock. Install a metal tube with valve facing down if required. Put th
10、e metal tube assembly as close to the radiator as possible. 4.1.3 Install the thermocouple stinger in the “heater in line“ and the “under thermostat area“. 4.1.4 Completely pack the cooling system using a coolant mixture according to VTS or vehicle service manual (default value: 50/50 water/glycol m
11、ixture). 4.1.4.1 A packed system is verified by visual inspection of the sight glass in the upper radiator hose and the level of the coolant in the overflow bottle, or surge tank. 4.1.4.1.1 The visual inspection of the sight glass is done with the coolant at approximately 105 C and the engine runnin
12、g at a speed between 1500 rpm and 3000 rpm. The coolant in the sight glass should be dark in color without air bubbles. If coolant turns milky in color, then the system is not packed and should be packed according to 4.3.17 thru 4.3.19. 4.1.4.1.2 System is degassed if level of coolant in the overflo
13、w bottle or surge tank has not changed for more than ( 3) mm at (21 3) C. 4.2 Conditions. 4.2.1 Environmental Conditions. Not applicable. 4.2.2 Test Conditions. Deviations from the requirements of this standard shall have been agreed upon. Such requirements shall be specified on component drawings,
14、test certificates, reports, etc. 4.3 Instructions. For Overflow Bottle Systems. 4.3.1 With the coolant at room temperature (21 3) C), remove the radiator cap. 4.3.2 Disconnect overflow bottle hose from the radiator and remove the overflow bottle from the vehicle. 4.3.3 Drain coolant from radiator in
15、to a catch pan by opening the radiator draincock or the “HOKE“ valve installed in the lower radiator hose. Drain the engine in a similar fashion by removing the block drain plugs. Drain the heater core. It may be necessary to use shop air to blow remaining coolant out of the heater core. 4.3.4 Calib
16、rate the overflow bottle. 4.3.4.1 Place a piece of duct tape vertically on the bottle relative to the installed vehicle position. Tape is to be visible when the bottle is installed on vehicle. 4.3.4.2 The cold mark on the bottle is to be used and marked as the “ZERO REFERENCE“ Line (“Zero Ref. Line“
17、). Position the bottle on a bench in the same position as it sits in the vehicle, and secure it. Determine how many milliliters are required to reach the “Zero Ref. Line“, and record this value on the data sheet in Appendix A. 4.3.4.3 Empty the bottle in 50 mL increments and mark the bottle at each
18、increment. Do this until no coolant can be drained from the overflow bottle. 4.3.4.4 Fill the overflow bottle to the “Zero Ref. Line“. Pour 50 mL at a time into the bottle and mark each increment on the tape. Increments larger than 50 mL may be used if the tape becomes too crowded, however, incremen
19、ts should not be larger than 100 mL in order to ensure good accuracy. See Figure 1 for calibrated overflow bottle description. 4.3.4.5 Install overflow bottle back on vehicle, but do not connect overflow bottle hose to radiator. Plug off radiator nipple with a vacuum boot plug. 4.3.5 Close radiator
20、draincock or “HOKE“ valve, whichever is used. Reinstall the block drain plugs. 4.3.6 Measure the amount of coolant removed and record this number on the data sheet in Appendix A. 4.3.7 Connect overflow bottle hose to radiator. Copyright General Motors Company Provided by IHS under license with Gener
21、al Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14905 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 3 of 6 Figure 1: Calibrated Overflow Bottle Description 4.3.8 Using a 500 mL be
22、aker, fill the cooling system, using the production fill point, for 5 minutes or until the coolant level is at the top of the filler neck. Fill for a maximum of 10 minutes. 4.3.9 Fill overflow bottle to “Zero Ref. Line“ with coolant mixture according to VTS or vehicle service manual, Note: Do not us
23、e the coolant that was previously drained from the system. Record the total amount of coolant added in the data sheet in Appendix A. 4.3.10 Set the Heating Ventilation Air Conditioning (HVAC) control head to Off. If any valves are present in the system, ensure they are open. 4.3.11 Start the engine
24、and a stopwatch. Monitor the “heater in“ and “under thermostat“ thermocouples. If the coolant temperature does not increase by at least 10 C within 3 minutes of the test, abort and shut off engine. 4.3.12 Add coolant as required to the lower edge of the filler neck until the upper radiator hose is h
25、ot, and then cap the radiator. Stop the stopwatch and note the coolant temperature, the amount of coolant added and the time at which the pressure cap was installed; record this data in the provided spaces on the data sheet in Appendix A. 4.3.13 Measure and pour the remainder of coolant into the ove
26、rflow bottle. 4.3.14 Start the engine and a stopwatch; let the engine idle. If the coolant temperature does not increase by at least 10 C within 3 minutes of the test, abort and shut off engine. 4.3.15 After the initial 3 minute idle is complete, manually (or with the use of a Multiple Diagnostic In
27、terface (MDI) unit) hold the engine speed at (2500 250) rpm. Hold at this engine speed for 10 minutes after engine cooling fan initially turns on (or 105 C coolant temperature for engine driven fans). Record the coolant temperature and the level of coolant in the overflow bottle in Appendix A. Shut
28、off the engine. Use a fan to cool the engine and coolant. 4.3.16 When the coolant has cooled down to (21 3) C, record the amount of coolant in the overflow bottle on the data sheet in Appendix A. 4.3.17 Start the engine and manually (or with the use of a MDI unit) hold the engine speed at (2500 250)
29、 rpm for 10 minutes after fan initially turns on (or until 105 C coolant temperature in the case of engine driven fans). 4.3.17.1 At the end of the 10 minutes (or 105 C coolant temperature for engine driven fans), record the coolant temperature and the level of coolant in the surge tank. Observe the
30、 color of the coolant in the sight glass. Shut off the engine. Use a fan to cool the engine and coolant. 4.3.18 With the coolant cooled down to (21 3) C, record the amount of coolant in the overflow bottle on the data sheet in Appendix A. 4.3.19 Repeat steps 4.3.17 thru 4.3.18 until no air is presen
31、t in the sight glass when the engine speed is increased. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14905 Copyright 2011 General Mot
32、ors Company All Rights Reserved December 2011 Page 4 of 6 Note: The level of coolant in the overflow bottle should not change more than ( 3) mm at (21 3) C for two consecutive thermal cycles. The total number of thermal cycles for degassing the system should not exceed three. 4.4 Instructions for Su
33、rge Tank Systems. 4.4.1 With the coolant at room temperature (21 3) C), remove the surge tank cap. 4.4.2 Drain coolant from radiator into a catch pan by opening the radiator draincock, “HOKE“ valve installed in the lower radiator hose or best practice (without draincock). Drain the engine in a simil
34、ar fashion by removing the block drain plugs. Drain the heater core. It may be necessary to use shop air to blow remaining coolant out of the heater core. Measure the amount of removed coolant and record this value on the data sheet in Appendix A. 4.4.3 Close radiator draincock or “HOKE“ valve (whic
35、hever is used). Reinstall the block drain plugs. Open any vent valves, screws or other release venting devices. Static fill the coolant system up to the cold fill mark for 5 minutes or until the level of coolant in the surge tank remains stable at the cold fill line. Fill for a maximum of 10 minutes
36、. Record the amount of coolant added on the data sheet in Appendix A. 4.4.4 Calibrate the surge tank. 4.4.4.1 To calibrate the surge tank, place a piece of duct tape vertically on the tank relative to the installed vehicle position. 4.4.4.2 Either clamp off the surge tank outlet hose using hose clam
37、ping pliers, or removes the surge tank and plug the outlet fitting. 4.4.4.3 The cold mark on the bottle is to be used and marked as the “Zero Ref. Line“. Determine how many milliliters are required to reach the zero reference line and record this value on the data sheet in Appendix A. 4.4.4.4 Empty
38、the tank in 50 mL increments and mark the tank at each increment. Do this until no coolant can be drained from the surge tank. 4.4.4.5 Fill the surge tank to the “Zero Ref. Line“. Pour 50 mL at a time into the tank and mark each increment onto the tape. Increments larger than 50 mL may be used if th
39、e tape becomes too crowded, however, increments should not be larger than 100 mL in order to obtain good accuracy. See Figure 1 for calibrated surge tank description. During this operation, close all venting devices as soon as liquid starts to exit. Record all surge tank data on the data sheet in Ap
40、pendix A. 4.4.5 Set the HVAC control head to Off. If any valves are present in the system ensure they are open. 4.4.6 Start the engine and a stopwatch; let the engine idle. If the coolant temperature does not increase by at least 10 C within 3 minutes of the test, abort and shut off engine 4.4.7 Add
41、 coolant as required to the surge tank until the upper radiator hose is hot, add the remaining coolant drained from the system, and cap the surge tank. Stop the stopwatch and note the coolant temperature. Record the amount of coolant added, record the coolant level on the surge tank and the time at
42、which the pressure cap was installed on the data sheet in Appendix A. 4.4.8 After the initial 3 minute idle is complete, manually (or with the use of a MDI unit) hold the engine speed at (2500 250) rpm. Hold at this engine speed for 10 minutes after engine cooling fan initially turns on (or until 10
43、5 C coolant temperature in the case of engine driven fans). 4.4.9 At the end of the 10 minutes, (or 105 C coolant temperature for engine driven fans), record the coolant temperature and the level of coolant in the surge tank and shut off the engine. Use a fan to cool the engine and coolant. 4.4.10 W
44、hen the coolant has cooled down to (21 3) C, record the level of coolant in the surge tank in Appendix A. 4.4.11 Start the engine and manually (or with the use of a MDI unit) hold the engine speed at (2500 250) rpm for 10 minutes after fan initially turns on (or until 105 C coolant temperature in th
45、e case of engine driven fans). 4.4.12 At the end of the 10 minutes (or 105 C coolant temperature for engine driven fans), record the coolant temperature and the level of coolant in the surge tank. Observe the color of the coolant in the sight glass. Shut off the engine. Use a fan to cool the engine
46、and coolant. 4.4.13 When the coolant has cooled down to (21 3) C, record the level of coolant in the surge tank. 4.4.14 Repeat steps 4.4.11 thru 4.4.13 until no air is present in the sight glass when the engine speed is increased. Copyright General Motors Company Provided by IHS under license with G
47、eneral Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW14905 Copyright 2011 General Motors Company All Rights Reserved December 2011 Page 5 of 6 Note: The level of coolant in the surge tank should be within ( 3) m
48、m at (21 3) C for two consecutive thermal cycles. The total number of thermal cycles for degassing the system should not exceed three. 5 Data 5.1 Calculations. According to Appendix A. 5.2 Interpretation of Results. Not applicable. 5.3 Test Documentation. All data to be recorded on the data sheet in
49、 Appendix A. 6 Safety This standard may involve hazardous materials, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 7 Notes 7.1 Glossary. “HOKE“ Valve: A fluid control
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