Adding Coolant

6.7L

Special Tools:






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.





1. Close radiator drain plug.

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

3. If using funnel 8195:

a. Remove cooling system pressure cap. Attach Filling Aid Funnel (8195) , to coolant pressure container filler neck.

b. Use the supplied clip to pinch overflow hose.

c. Pour coolant into the larger section of Filling Aid Funnel (the smaller section of funnel is to allow air to escape).

d. Continue filling until a steady stream of coolant flows from the vent hole.

e. Install vent fitting when coolant is free of bubbles.

f. Tighten the bleed plug to 10 Nm (89 in. lbs.).

g. Remove clip from overflow hose.

h. Allow coolant in Filling Aid Funnel to drain into overflow chamber of pressure container.

i. Remove Filling Aid Funnel. (8195)

j. Install the pressure cap.

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.






NOTE:
The (8195A)does not require pinching off the overflow hose. The adapter seal prevents liquid from entering the overflow during coolant fill.

4. If using Special Tool (8195A):

a. Select the appropriate fitting extension (3) and locking ring (2) and attach to the fill neck of the cooling system.

b. Make sure the adapter seal fits firmly against the inside of the fill neck base to ensure a good seal. After the extension and locking ring are installed, make sure the extension can not be moved. This will confirm a good seal.

c. Attach the funnel (1) to the extension (1) and fill with coolant.

d. Add coolant to the funnel. Continue to add coolant until a steady stream of coolant flows from the vent hole.

e. Install the vent fitting when coolant is free of bubbles.

f. Tighten the vent fitting to 6 Nm (55 in. lbs.).

g. Install the stopper (4) into the funnel base. The stopper will prevent the fluid that is left in the funnel from spilling out when separated from the extension.

h. Remove the funnel, extension and locking ring and install the cap.

5. 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.

6. Slowly loosen vent fitting (1) to purge any trapped air. If air is still present. Repeat step 3 - 5.

7. Check coolant level in coolant recovery container. Fill to FULL line.

8. 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.

9. Remove Tool. Install radiator cap.