Charge Air Cooling System Draining and Filling (Static)

Charge Air Cooling System Draining and Filling (Static)

Special Tools

* 7000081 - Tech 2 Kit

* J 26568 - Coolant and Battery Fluid Tester

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 Service and Repair.

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 Service and Repair.

11. Lower the vehicle.

Filling Procedure

Caution:
The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

Note:
The charge air cooling system is filled through the charge air cooler reservoir fill neck.

1. Remove the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement Service and Repair.





2. Loosen the bleeder screw (1) from the charge air cooler radiator on the top driver side of the charge air cooler.

Note:
Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water. It is necessary to maintain the coolant level within the cold fill level range on the charge air cooler reservoir to ensure all the air has been purged from the cooling system.

3. Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean, drinkable water to the cooling system until the coolant level reaches the top of the charge air cooler radiator at the bleeder screw opening. Refer to Approximate Fluid Capacities [1][2]Maintenance.

4. Install the bleeder screw (1) and tighten to 1.5 Nm (13 lb in).





5. Slowly add the coolant mixture to the charge air cooler reservoir until the coolant level is at the top of the cold fill level range on the reservoir.

Note:
Do not cycle the charge air coolant pump without the charge air cooling reservoir cap in place or loss of coolant will occur.

6. Install the cap to the charge air cooler reservoir.

7. Using a Tech 2 Scan Tool, cycle the charge air coolant pump ON for 2 seconds.

8. Cycle the charge air coolant pump OFF.

9. Remove the charge air cooler reservoir cap, and wait for the air bubbles to travel up the charge air cooler reservoir hose to the reservoir.

10. Slowly add the coolant mixture to the charge air cooler reservoir until the coolant level is at the top of the cold fill level range on the reservoir.

11. Install the cap to the charge air cooler reservoir.

12. Repeat steps 7-11 until all of the air has been purged from the system and no air bubbles travel up the charge air cooler reservoir hose to the reservoir.

13. Install the charge air cooler reservoir cap and cycle the charge air coolant pump ON for 5 minutes.

14. Cycle the charge air coolant pump OFF.

15. Remove the charge air cooler reservoir cap and allow the vehicle to sit for 15 minutes.

16. Slowly add the coolant mixture to the charge air cooler reservoir until the coolant level is at the top of the cold fill level range on the reservoir.

17. Inspect the concentration of the charge air cooling system coolant using the J 26568 - Coolant and Battery Fluid Tester.

18. Install the charge air cooler reservoir cap.

19. Inspect the cooling system for leaks.

20. Install the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement Service and Repair.

21. Rinse away any excess coolant from the engine and the engine compartment.