without Radiator Refiller

Fuel and Turbocharger Cooling System Draining, Filling and Bleeding









Filling and bleeding without RADIATOR REFILLER

1. Remove the front bumper. For additional information, refer to Bumper.

2. NOTE: Make sure the system was completely drained before attempting to fill and bleed the system.

Connect the coolant hoses at the fuel cooling system radiator.





3. NOTE: The side bolt does not have to be removed to remove the fuel cooling system radiator.

Remove the fuel cooling system radiator top bolt.





4. Slide the fuel and turbocharger cooling system radiator up off the side bolt and position the radiator horizontally.





5. Remove the plug from the turbocharger actuator cooler.





6. Fill the fuel and turbocharger cooling system through the expansion tank until the coolant reaches the top of the turbocharger actuator plug hole.

7. Install the turbocharger cooler plug.
- Tighten to 33 Nm (24 lb-ft).





8. Disconnect the coolant pump-to-fuel cooler hose from the cooler and place the hose in a clear container.





9. NOTE: The engine has to be running and the fuel temperature has to be above 35°C (95°F) before the fuel cooling pump will be turned on by the PCM.

NOTE: Top off the coolant expansion tank as needed.

Start the engine and run the engine until the coolant pump turns on and the coolant starts to fill the container (approximately 15 minutes from when the pump turns on).

10. Turn the ignition switch to the OFF position.

11. Connect the coolant pump-to-fuel cooler hose to the fuel cooler.





12. Remove the plug from the turbocharger actuator cooler.





13. Fill the fuel and turbocharger cooling system through the expansion tank until the coolant reaches the top of the turbocharger actuator plug hole.

14. Install the turbocharger actuator cooler plug.
- Tighten to 33 Nm (24 lb-ft).





15. Start the engine and continue to fill the coolant expansion tank until the coolant in the coolant expansion tank is visible through the site glass.

16. NOTE: An operating coolant pump that squeals indicates either:
- the system is not completely filled or bled.
- the coolant pump is bad and must be replaced.

If the coolant pump squeals, drain the cooling system, fill and bleed the cooling system again.
- If the coolant pump still squeals, replace the coolant pump. For addition information, refer to Coolant Pump Coolant Pump - Fuel Charging and Controls.

17. Position the fuel and turbocharger cooling system radiator and install the bolt.
- Tighten to 12 Nm (106 lb-in).





18. Top off the coolant expansion tank, if necessary and until coolant is visible throughout the sight glass.

19. Install the pressure relief cap.

20. Clean any coolant that may have spilled on the engine components.

21. Install the front bumper. For additional information, refer to Bumper.