Charge Air Cooling System Draining and Filling (Static)
Charge Air Cooling System Draining and Filling (LSA Static)
Draining Procedure
Warning
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
Note: Make sure the intercooler system is cool and that the pump is not in the ON position.
1. Open the hood and remove the intake manifold cover. Refer to Intake Manifold Cover Replacement - Front Intake Manifold Cover Replacement - Front.
2. Orientate the charge air coolant (CAC) quick connect fitting to the vertical position.
3. Rotate and remove the charge air coolant cap (1).
4. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
5. Remove the front bumper fascia air deflector. Refer to Radiator Air Inlet Duct Replacement Radiator Air Inlet Duct ReplacementRadiator Air Inlet Duct Replacement (LSA) Radiator Air Inlet Duct Replacement.
6. Remove the drain plug at the (CAC) (1).
7. Allow the system to fully drain into a clean container.
8. Measure and record the amount of coolant drained.
Caution: Refer to Fastener Caution Fastener Caution.
9. Install and tighten the drain plug to 9.6 Nm (85 lb in).
10. Lower the vehicle.
Filling Procedure
Note: It is critical that the system must be completely free of air to prevent CAC pump noise and loss of system performance.
1. Install absorbent rags under the (CAC) quick connect fitting to absorb any coolant loss.
Note: Do NOT remove the right hand upper (CAC) vent plug.
2. Use a long 3/8" extension through the front grill to loosen the vent plug on the right hand upper (CAC) end tank.
Note: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
3. Ensure the CAC quick connect fitting is in the vertical position.
4. Slowly fill coolant through the (CAC) quick connect until the coolant is visible at the vent port.
Caution: Refer to Fastener Caution Fastener Caution.
5. Tighten the vent port plug to 9.6 Nm (85 lb in).
6. Slowly fill coolant through the (CAC) quick connect until the coolant stabilizes within the fitting.
7. Install the charge air coolant cap (1).
Note: Use one of the following methods to cycle the coolant with the (CAC) pump.
8. Using the Tech 2, cycle the (CAC) pump ON for 60 seconds and then to the OFF position.
Or set the parking brake and ensure the transmission is in PARK or Neutral. Start the engine and allow the (CAC) pump to run for 60 seconds. Turn engine OFF.
9. Allow the system to stabilize for 60 seconds and remove the charge air coolant cap.
10. Continue to slowly fill the (CAC) cooling system with coolant until the level stabilizes within the fitting.
11. Install the charge air coolant cap.
12. Repeat steps 6-10 until additional coolant can not be added through the charge air coolant cap into the system. Refer to Approximate Fluid Capacities [1][2]Capacity Specifications
13. Inspect the CAC cooling system for leaks.
14. Remove the absorbent rags.
15. Rinse away any excess coolant from the engine and the engine compartment.
16. Orientate the charge air coolant (CAC) quick connect fitting to the previously installed position to allow for the engine cover clearance.
17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement - Front Intake Manifold Cover Replacement - Front.
18. Install the front bumper fascia air deflector. Refer to Radiator Air Inlet Duct Replacement Radiator Air Inlet Duct ReplacementRadiator Air Inlet Duct Replacement (LSA) Radiator Air Inlet Duct Replacement.