Diesel Engine
Cooling System Draining, Filling and Bleeding
Special Tool(s)
Draining
WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.
NOTICE:
- Always fill the cooling system with the manufacturer's specified coolant. If a non-specified coolant has been used the cooling system MUST be chemically flushed. Refer to Cooling System Flushing Without Oil Contamination in this section. Failure to follow these instructions may result in damage to the cooling system.
- Recover the coolant in a suitable, clean container. If the coolant is contaminated with a radiator sealant or stop-leak, oil or combustion by-products it must be recycled or disposed of correctly and the system MUST be chemically flushed. If the cooling system is drained to make a repair to a cooling system component where evidence is seen of aluminum erosion or cavitation, the coolant must be recycled or disposed of correctly and the system MUST be flushed out with water to remove all particulate contaminants and MUST be chemically flushed. Refer to Cooling System Flushing Without Oil Contamination in this section. Failure to follow these instructions may result in damage to the cooling system.
NOTE:
- During normal vehicle operation, Motorcraft(R) Orange Antifreeze/Coolant may change color from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change does not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the system to be flushed, or the engine coolant to be replaced.
- Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the pressure relief cap from the degas bottle.
4. Place a suitable container below the radiator draincock.
5. Open the radiator draincock and drain the coolant into a suitable clean container.
6. Close the radiator draincock when finished.
7. Remove the RH fender splash shield.
8. Completely cover the starter with waterproof plastic.
9. NOTE: Use of a long ball-end hex bit socket eases removal of the drain plug.
Remove the drain plug and drain the coolant from the RH side of the engine block.
- Install the drain plug when finished and tighten to 60 Nm (44 lb-ft).
10. Remove the waterproof plastic from the starter.
11. Release the clamp, disconnect the engine-to-engine oil cooler hose from the engine oil cooler and drain the coolant from the LH side of the cylinder block.
- Connect the engine-to-engine oil cooler hose and position the clamp when finished.
Filling and Bleeding with Vacuum Cooling System Filler
NOTICE:
- Before filling the cooling system, evaluate the cooling system condition. For additional information, refer to Cooling System Condition Evaluation in this section. Failure to follow these instructions can result in damage to the engine.
- Vehicle cooling systems are filled with Motorcraft(R) Orange Antifreeze/Coolant. Always fill the cooling system with Motorcraft(R) Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft(R) Orange Antifreeze/Coolant. Failure to follow these instructions may damage the engine or cooling system.
- Engine coolant provides freeze protection, boil protection, corrosion protection and cooling efficiency to the engine and cooling components. In order to obtain these protections, maintain the engine coolant at the correct concentration and fluid level. Failure to follow these instructions may damage the engine or cooling system.
- To maintain the integrity of the coolant and the cooling system:
- Do not mix coolant types. Mixing coolants degrades the coolant corrosion protection.
- Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
- Do not mix with recycled coolant. Use of such coolant may harm the engine and cooling system components.
When adding or topping off the engine coolant:
a. measure the coolant concentration in the vehicle using Coolant Battery Refractometer ROB75240 or equivalent.
b. determine the concentration based on the vehicle duty cycle of extreme hot or cold operating conditions.
c. add/top off or adjust the coolant as follows:
- for concentrations measured 48/52 to 50/50 (equates to a freeze point between -34°C and -37°C [-30F and -34°F]) use Motorcraft(R) Orange Antifreeze/Coolant Prediluted to maintain a coolant concentration in this same range.
- for all other concentrations, use Motorcraft(R) Orange Antifreeze/Coolant Concentrated and/or distilled water to get to the desired concentration.
When filling the engine coolant after a flush procedure, use a mixture of Motorcraft(R) Orange Antifreeze/Coolant Concentrated and distilled water to get to the desired concentration.
NOTE: Filling the cooling system with a vacuum cooling system filler is the preferred method.
1. Install the RH fender splash shield.
2. Connect the battery ground cable.
3. NOTICE: With the engine cold, fill vehicles to within the cold fill range shown on the degas bottle. This fill level allows for coolant expansion. Overfilling the degas bottle may result in damage to the pressure cap, which can cause the engine to overheat.
Install the vacuum cooling system filler and follow the tool manufacturer instructions to fill and bleed the cooling system.
- Recommended coolant concentration is 48/52 to 50/50 (freeze protection -34°C to -37°C [-30°F to -34°F]) engine coolant to distilled water.
- For extremely cold climates (less than -37°C [-34°F]):
- It may be necessary to increase the coolant concentration above 50%.
- NEVER increase the coolant concentration above 60%.
- Maximum coolant concentration is 60/40 for cold weather areas.
- A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F).
- Engine coolant concentration above 60% decreases the overheat protection characteristics of the engine coolant and may damage the engine.
- For extremely hot climates:
- It is still necessary to maintain the coolant concentration above 40%.
- NEVER decrease the coolant concentration below 40%.
- Minimum coolant concentration is 40/60 for warm weather areas.
- A coolant concentration of 40% provides freeze point protection down to -26°C (-15°F).
- Engine coolant concentration below 40% decreases the corrosion and freeze protection characteristics of the engine coolant and may damage the engine.
- Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 (freeze protection -34°C to -37°C [-30°F to -34°F]) mixture of engine coolant and distilled water for optimum cooling system and engine protection.
4. NOTE: Failure to block the radiator off will require more time before the thermostat will open.
Position a piece of cardboard on the driver side half of the radiator.
5. Fill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
6. Run the engine at 2,000 RPM for 2 minutes.
7. Bring the engine to an idle.
- Determine if the thermostat has opened by feeling the temperature of the upper radiator hose at the radiator. If the hose is cool then the thermostat has not opened. If the hose is warm or hot then the thermostat has opened.
8. If the coolant level has dropped below the minimum fill line then refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
9. Repeat Steps 3 through 5 until the thermostat opens.
- The coolant level will rise before the thermostat opens due to thermal expansion. The coolant level will drop after the thermostat opens due to air exiting the system.
10. Repeat Steps 3 and 5 until the coolant level stabilizes.
11. Stop the engine and remove the cardboard from the radiator.
12. Restart and idle the engine for 5 minutes to stabilize the coolant temperature.
13. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line.
- Install the degas bottle cap.
14. Verify that the cardboard has been removed from the radiator.
Filling and Bleeding without a Vacuum Cooling System Filler
NOTICE:
- Before filling the cooling system, evaluate the cooling system condition. For additional information, refer to Cooling System Condition Evaluation in this section. Failure to follow these instructions can result in damage to the engine.
- Vehicle cooling systems are filled with Motorcraft(R) Orange Antifreeze/Coolant. Always fill the cooling system with Motorcraft(R) Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft(R) Orange Antifreeze/Coolant. Failure to follow these instructions may damage the engine or cooling system.
- Engine coolant provides freeze protection, boil protection, corrosion protection and cooling efficiency to the engine and cooling components. In order to obtain these protections, maintain the engine coolant at the correct concentration and fluid level. Failure to follow these instructions may damage the engine or cooling system.
- To maintain the integrity of the coolant and the cooling system:
- Do not mix coolant types. Mixing coolants degrades the coolant corrosion protection.
- Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
- Do not mix with recycled coolant. Use of such coolant may harm the engine and cooling system components.
When adding or topping off the engine coolant:
a. measure the coolant concentration in the vehicle using Coolant Battery Refractometer ROB75240 or equivalent.
b. determine the concentrating based on the vehicle duty cycle of extreme hot or cold operating conditions.
c. add/top off or adjust the coolant as follows:
- for concentrations measured 48/52 to 50/50 (equates to a freeze point between -34°C and -37°C [-30F and -34°F]) use Motorcraft(R) Orange Antifreeze/Coolant Prediluted to maintain a coolant concentration in this same range.
- for all other concentrations, use Motorcraft(R) Orange Antifreeze/Coolant Concentrated and/or distilled water to get to the desired concentration.
When filling the engine coolant after a flush procedure, use a mixture of Motorcraft(R) Orange Antifreeze/Coolant Concentrated and distilled water to get to the desired concentration.
NOTE: Filling the cooling system with a vacuum cooling system filler is the preferred method. Carry out the following procedure only if a vacuum cooling system filler is not available.
1. Install the RH fender splash shield.
2. Connect the battery ground cable.
3. NOTE: Failure to block the radiator off will require more time before the thermostat will open.
Position a piece of cardboard on the driver side half of the radiator.
4. NOTE: The degas bottle cap must be loose so that the cooling system does not get pressurized.
Fill the degas bottle to the maximum fill line.
- Recommended coolant concentration is 48/52 to 50/50 (freeze protection -34°C to -37°C [-30°F to -34°F]) engine coolant to distilled water.
- For extremely cold climates (less than -37°C [-34°F]):
- It may be necessary to increase the coolant concentration above 50%.
- NEVER increase the coolant concentration above 60%.
- Maximum coolant concentration is 60/40 for cold weather areas.
- A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F).
- Engine coolant concentration above 60% decreases the overheat protection characteristics of the engine coolant and may damage the engine.
- For extremely hot climates:
- It is still necessary to maintain the coolant concentration above 40%.
- NEVER decrease the coolant concentration below 40%.
- Minimum coolant concentration is 40/60 for warm weather areas.
- A coolant concentration of 40% provides freeze point protection down to -26°C (-15°F).
- Engine coolant concentration below 40% decreases the corrosion and freeze protection characteristics of the engine coolant and may damage the engine.
- Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 (freeze protection -34°C to -37°C [-30°F to -34°F]) mixture of engine coolant and distilled water for optimum cooling system and engine protection.
5. Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
6. Start and idle the engine until the coolant level stabilizes.
7. Refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
8. Run the engine at 2,000 RPM for 2 minutes.
9. Bring the engine to an idle.
- Determine if the thermostat has opened by feeling the temperature of the upper radiator hose at the radiator. If the hose is cool then the thermostat has not opened. If the hose is warm or hot then the thermostat has opened.
10. If the coolant level has dropped below the minimum fill line then refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
11. Repeat Steps 5 through 7 until the thermostat opens.
- The coolant level will rise before the thermostat opens due to thermal expansion. The coolant level will drop after the thermostat opens due to air exiting the system.
12. Repeat Steps 5 and 7 until the coolant level stabilizes.
13. Stop the engine and remove the cardboard from the radiator.
14. Restart and idle the engine for 5 minutes to stabilize the coolant temperature.
15. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line.
- Install the degas bottle cap.
16. Verify that the cardboard has been removed from the radiator.