Filling

FILLING - 6.7L DIESEL ENGINE

Clean cooling system prior to refilling Service and Repair.

1. Close radiator drain plug.

CAUTION: All air must be purged from the 6.7L engine when refilling the cooling system. Failure to do so can cause EGR Cooler cracking which can lead to catastrophic engine and exhaust system damage.





2. Remove the vent fitting (1) located near the EGR cooler (2).

NOTE: The diesel engine is equipped with two one-way check valves (jiggle pins). The check valves are used as a servicing feature and will vent air when the system is being filled. Water pressure (or flow) will hold the valves closed.

3. Using Tool 8195 on the 6.9L, fill the cooling system with coolant mixture Description.
4. Fill system until coolant comes out of vent hole.
5. Install vent fitting when coolant is present at the vent tube. Tighten to 6 Nm (55 in. lbs.).
6. Squeeze the upper radiator hose and add additional coolant as necessary.
7. Start and operated the engine. Take the vehicle on a test drive till operating temperature is reached. Shut the engine down and wait till engine is cool.
8. Slowly loosen vent fitting (1) to purge any trapped air. If air is still present. Repeat step 3 - 5.
9. Check coolant level in coolant recovery container. Fill to FULL line.
10. The volume of coolant added to the engine must be within 1.5 quarts of the volume drained. If this requirement has not been met, repeat steps 2 - 9.
11. Remove Tool 8195. Install radiator cap.

FILLING - 5.9L DIESEL ENGINE





Clean cooling system prior to refilling Service and Repair.

1. Close radiator drain plug.
2. Using Tool 8195 on the 5.9L, fill the cooling system with coolant mixture Description.
3. Squeeze the upper radiator hose and add additional coolant as necessary.
4. Fill coolant recovery container to the FULL mark.
5. Start and operate engine until thermostat opens. Upper radiator hose should be warm to touch.
6. Accelerate engine from idle to 2500 RPM five times. (throttle snaps)
7. Shut off engine. Allowing cooling system to settle. Fill coolant recovery container to FULL line.
8. Start and operate engine. Take vehicle for a test drive till operating temperature is reached.
9. Shut off engine. Allow engine to cool. Fill coolant recovery container to FULL line.
10. The volume of coolant added to the engine must be within 1.5 quarts of the volume drained. If this requirement has not been met, repeat steps 1 - 9.
11. Remove Tool 8195. Install radiator cap.