Charge Air Cooling System Coolant Level Inspection

Charge Air Cooling System Coolant Level Inspection






Important: Make sure the intercooler system is cool and that the pump is not in the ON position.


1. Remove the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair) .
2. Remove the charge air coolant cap.

Important: It is normal to have a very small pocket of air at the top of the system below the fill cap on a properly filled charge air cooling system.


3. Verify that coolant is visible near to top of the opening.

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


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


4. 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 the level is slightly below the charge air coolant cap port. Refer to Approximate Fluid Capacities (Specifications) .




5. Ensure the charge air cooler cooling fill cap is installed in the proper orientation.

* The alignment boss (1) is at the rear of the charge air cooler manifold.
* The alignment boss (1) is at the front of the charge air cooler cooling filling cap.






Notice: Refer to Fastener Notice (Fastener Notice) .

6. Install the charge air coolant cap bolts.

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

7. Install the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair) .