Charge Air Cooling System Draining and Filling (GE 47716)
Charge Air Cooling System Draining and Filling (GE 47716)
Special Tools
* GE-47716 - Vac N Fill Coolant Refill Tool
* J 26568 - Coolant and Battery Fluid Tester
* J 46143 - Cooling System Adapter
Draining Procedure
Warning
To avoid being burned, do not remove the charge air coolant cap while the system is hot. The cooling system will release scalding fluid and steam under pressure if charge air coolant cap is removed while the system is still hot.
Note: Make sure the intercooler system is cool and the pump is not running.
1. Remove the cap from the charge air cooler reservoir.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
3. Remove the front air deflector. Refer to Front Air Deflector Replacement .
4. Place a drain pan under the charge air cooler radiator.
5. Remove the charge air cooler radiator drain plug (1) from the bottom passenger side of the charge air cooler.
6. Drain the charge air cooling system.
7. Inspect the coolant.
8. Follow the appropriate procedure based on the condition of the coolant.
* Normal in appearance - follow the filling procedure
* Discolored - follow the flush procedure. Refer to Flushing (Powertrain) Flushing (Powertrain)Flushing (Charge Air Cooling) Flushing (Charge Air Cooling).
Caution: Refer to Fastener Caution Fastener Caution.
9. Install the charge air cooler radiator drain plug (1) and tighten to 1.5 Nm (13 lb in).
10. Install the front air deflector. Refer to Front Air Deflector Replacement .
11. Lower the vehicle.
Vac N Fill Procedure
Note: To prevent boiling of the coolant/water mixture in the vehicles cooling system, do not apply vacuum to a cooling system above 49 degrees C (120 degrees F). The tool will not operate properly when the coolant is boiling.
1. Install the J 46143 - Cooling System Adapter onto the charge air cooler reservoir fill neck.
Warning
To avoid being burned, do not remove the charge air coolant cap while the system is hot. The cooling system will release scalding fluid and steam under pressure if charge air coolant cap is removed while the system is still hot.
2. Attach the Vac N Fill cap to the J 46143 - Cooling System Adapter.
3. Attach the vacuum gauge assembly to the Vac N Fill cap.
4. Attach the fill hose to the barb fitting on the vacuum gauge assembly.
Ensure that the valve is closed.
Note:
* Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
* Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.
5. Pour the coolant mixture into the graduated reservoir.
6. Place the fill hose in the graduated reservoir.
Note: Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.
7. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
8. Attach the venturi assembly to the vacuum tank.
9. Attach a shop air hose to the venturi assembly.
Ensure the valve on the venturi assembly is closed.
10. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
11. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
12. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg).
Cooling hoses may start to collapse. This is normal due to vacuum draw.
13. To aid in the fill process, position the graduated reservoir above the coolant fill port.
14. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
15. Close the valve on the venturi assembly.
16. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.
If vacuum loss is observed, refer to Loss of Coolant Loss of Coolant.
17. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
18. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 11-17.
19. Detach the Vac N Fill cap from the J 46143 - Cooling System Adapter.
20. Remove the J 46143 - Cooling System Adapter from the coolant surge tank.
21. Add coolant to the system as necessary.
22. Inspect the concentration of the coolant mixture using J 26568 - Coolant and Battery Fluid Tester.
Note: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.
23. Detach the vacuum hose from the vacuum gauge assembly.
24. Attach the extraction hose to the vacuum hose.
25. Open the valve on the venturi assembly to start a vacuum draw.
26. Use the extraction hose to draw out coolant to the proper level.
27. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.
28. Install the surge tank cap.