Steps 101-130
Cooling System Flushing - With Fluid Contamination
NOTE: For the coolant flow diagrams, refer to Engine Cooling Engine Cooling in the Description and Operation information.
101. Release the clamp and disconnect the quick-connect coupling from the oil cooler return hose.
102. Using a coupling adapter and 2 hose clamps, connect the fresh water supply hose to the oil cooler return hose.
103. Using a hose clamp, connect the drain hose to the engine oil cooler feed pipe.
104. Turn on the fresh water supply and allow the water to flush the engine oil cooler until the drain water is free of foam, bubbles or discoloration.
105. While the water is flushing the oil cooler, use a clear, clean approximately 1 L (1 qt) container to collect some of the drain water and verify the drain water is free of foam, bubbles or discoloration.
106. If the drain water in step 105 shows signs of foam, bubbles or discoloration, continue to flush the oil cooler with fresh water and repeat step 105 until the drain water is free of foam, bubbles or discoloration.
107. Turn off the fresh water supply.
108. Disconnect the fresh water supply hose from the engine oil cooler return hose.
109. Disconnect the drain hose from the engine oil cooler feed pipe.
110. Connect the quick connect coupling to the engine oil cooler return hose and position the clamp.
111. Push the spring clip in place and connect the engine oil cooler return hose to the lower radiator hose quick connect coupling, making sure the coupling is secure.
112. Connect the engine-to-engine oil cooler hose to the engine oil cooler and position the clamp.
113. Install the starter. For additional information , refer to Starting System - Diesel Engine Service and Repair.
114. Remove the hose pinch pliers from the upper radiator hose.
115. Install the ACL and the ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.
116. Fill the cooling system with low hardness, low chloride water. Tap water which is verified with Rotunda Water Test Strip 5 pack 328-00007 or equivalent is acceptable. Alternatively, use water treated by reverse osmosis, or water that is de-ionized or distilled.
Fill the cooling system with hot water.
1. Fill the degas bottle to the maximum fill line.
2. NOTE: The degas bottle cap must be loose so that the cooling system does not get pressurized.
Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
3. Start and idle the engine until the coolant level stabilizes.
4. If the coolant level drops below the minimum fill line 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.
5. Run the engine at 2,000 rpm for 2 minutes.
6. Bring the engine to an idle.
7. If the coolant level drops below the minimum fill line 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. Repeat Steps 5 through 7 until the coolant level stabilizes. Shut the engine off.
9. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line. Install the degas bottle cap.
117. 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.
Release the pressure in the cooling system by slowly turning the pressure relief cap 1/2 turn counterclockwise. When the pressure is released, remove the pressure relief cap.
118. Open the radiator draincock and drain the cooling system.
- After the cooling system drains, remove and discard the radiator draincock.
119. Release the clamp and disconnect the engine-to-engine oil cooler hose from the engine oil cooler and drain the cylinder block.
120. Remove the starter. For additional information, refer to Starting System - Diesel Engine Service and Repair.
121. Remove the RH cylinder block drain plug and drain the cylinder block.
122. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.
Pull the lower radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the lower radiator hose quick-connect coupling at the mid-point between the radiator tank and the engine, and drain all the water from the lower radiator hose.
- Connect the lower radiator hose quick-connect coupling when finished.
- To install, push the spring clip in place and connect the lower radiator hose quick connect coupling, making sure the coupling is secure.
123. Install a new radiator draincock.
- Make sure the radiator draincock is closed.
124. Release the clamp and remove the engine-to-engine oil cooler hose.
125. Install a new engine-to-engine oil cooler hose and position the clamps.
126. Install the RH cylinder block drain plug.
- Tighten to 60 Nm (44 lb-ft).
127. Install the starter. For additional information, refer to Starting System - Diesel Engine Service and Repair.
128. NOTE: Make sure the thermostat gasket is in place on the thermostat assembly prior to installation.
Using a new thermostat gasket, install the thermostats. For additional information, refer to Thermostat [1][2]Service and Repair.
129. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding Cooling System Draining, Filling and Bleeding.
130. Install a new pressure relief cap.