Draining and Filling Cooling System - Charge Air Cooling System (Static Fill)

Draining and Filling Cooling System - Charge Air Cooling System (Static Fill)

Tools Required

J 26568 Coolant and Battery Tester

Draining Procedure





Caution: To avoid being burned, do not remove the charge air coolant cap while the system is hot. The cooling system will release scalding fluid and steam under pressure if charge air coolant cap is removed while the system is still hot.

Important: Make sure the intercooler system is cool and the pump is not running.

1. Remove the charge air cooling system pressure cap (1).
2. Remove the charge air coolant cap (2).
3. Raise and support the vehicle. Refer to Vehicle Lifting.




4. Remove the front air deflector.
5. Place a drain pan under the charge air coolant radiator.
6. Remove the charge air coolant radiator drain plug.




7. Drain the charge air cooling system.
8. Inspect the coolant.
9. Follow the appropriate procedure based on the condition of the coolant.

* Normal in appearance - follow the filling procedure.
* Discolored - follow the flush procedure.

Notice: Refer to Fastener Notice.

10. Install the charge air coolant radiator drain plug.

Tighten the plug to 10 N.m (89 lb in).

11. Install the front air deflector.
12. Lower the vehicle.

Filling Procedure





Notice: The procedure below must be followed. Improper coolant level could result in poor system performance.

Important: The charge air cooling system is filled through the charge air coolant cap and the charge air coolant fill neck.

1. Loosen the charge air coolant radiator vent plug.
2. Place a shop towel around the charge air coolant radiator vent plug to absorb any leakage.





Important:
* Use a 50/50 mixture of DEX-COOL(R) antifreeze and clean drinkable water.

* Pour coolant in very small amounts to avoid coolant spillage from the charge air coolant port or from the funnel.

Using a small funnel, slowly fill the charge air cooling system through the charge air coolant cap port with a 50/50 coolant mixture until coolant is present at the charge air coolant radiator vent plug.
3. Hand tighten the charge air coolant radiator vent plug.




4. Using a small funnel, continue to slowly fill the charge air cooling system through the charge air coolant cap port until coolant is level with the charge air coolant cap port.

Important: Do not cycle the charge air cooling system without the charge air cooling cap in place or coolant loss will occur.

5. Install the charge air coolant cap.
6. Install the charge air coolant cap bolts

Tighten the plug to 10 N.m (89 lb in).




7. Slowly fill the charge air cooling system through the charge air coolant fill neck until coolant reaches the COLD FILL mark.

Important: Cycle the charge air coolant system by using the Tech 2 or by starting the engine.

8. Cycle the charge air cooling pump ON and continue to slowly fill through the charge air coolant fill neck until the level stabilizes at the COLD FILL mark.




9. Slowly loosen the charge air coolant radiator vent plug until coolant is present.
10. Remove the shop towel from around the vent port.
11. Tighten the charge air coolant radiator vent plug.

Tighten the plug to 10 N.m (89 lb in).

12. Continue to slowly fill through the charge air coolant fill neck until the level has stabilized at the COLD FILL mark.
13. Cycle the charge air coolant pump OFF.




14. Remove the charge air coolant cap bolts.
15. Remove the charge air coolant cap.
16. Ensure that coolant is almost level with the coolant cap fill port.
Top off with the 50/50 coolant mixture through the charge air coolant cap port, if necessary.
17. Install the charge air coolant cap.
18. Install the charge air coolant cap bolts.

Tighten the plug to 10 N.m (89 lb in).





Important: Do not cycle the charge air cooling system without the charge air cooling cap in place or loss of coolant will occur.

19. Cycle the charge air coolant pump ON for 3 minutes.
20. Cycle the charge air coolant pump OFF.
21. Fill through the charge air coolant fill neck until the level stabilizes at the COLD FILL mark.
22. Repeat steps 19-21 until level is stabilized at the COLD FILL mark with the charge air coolant pump in the OFF position.
23. Inspect the concentration of the engine coolant, using the J 26568.
24. Install the charge air cooling system pressure cap.
25. Inspect the charge air cooling system for leaks.