Charge Air Cooling System Draining and Filling (Vacuum Fill)
Charge Air Cooling System Draining and Filling (LSA Vacuum Fill)
Special Tools
* GE-26568 - Coolant and Battery Fluid tester
* GE-47716 - Vac-N-Fill Coolant Refill Tool
* GE-47716-20 - Cooling System Fill Adapter
For equivalent regional tools, refer to Special Tools Tools and Equipment.
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 air charge air coolant (CAC) quick connect fitting to the vertical position.
3. Rotate and remove the CAC cap.
4. Raise and suitable support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
5. Remove the lower radiator air inlet duct. 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 cock (1) from the CAC radiator.
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 cock (1) to 9.6 Nm (85 lb in).
10. Lower the vehicle.
Vac-N-Fill 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: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
2. Ensure the CAC quick connect fitting is in the vertical position.
3. Install the GE-47716-20 - Cooling System Fill Adapter to the CAC quick connect fitting.
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.
4. Attach the Vac-N-Fill gauge assembly to GE-47716-20 - Cooling System Fill Adapter.
5. Attach the vacuum gauge assembly to the Vac-N-Fill cap.
6. 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.
7. Pour the coolant mixture into the graduated reservoir.
8. 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.
9. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
10. Attach the venturi assembly to the vacuum tank.
11. Attach a shop air hose to the venturi assembly.
Ensure the valve on the venturi assembly is closed.
12. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
13. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
14. 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.
15. To aid in the fill process, position the graduated reservoir above the coolant fill port.
16. 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.
17. Close the valve on the venturi assembly.
18. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.
19. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
20. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 12-18.
21. Detach the Vac-N-Fill gauge assembly from the GE-47716-20 - Cooling System Fill Adapter.
22. Remove the GE-47716-20 - Cooling System Fill Adapter from the CAC quick connect fitting.
23. Install the charge air coolant cap.
Note: Use one of the following methods to cycle the coolant with the CAC pump.
24. Using the Tech 2, cycle the CAC pump ON for 60 seconds and then to the OFF position.
25. Or set the parking brake and ensure the transmission is in PARK or NEUTRAL. Start the engine and allow the CAC pump to run 60 seconds. Turn the engine OFF.
26. Allow the system to stabilize for 60 seconds and remove the CAC cap.
27. Continue to slowly fill the CAC cooling system with coolant until the level stabilizes within the fitting.
28. Install the CAC cap.
29. Repeat steps 6-10 until additional coolant can not be added through the CAC cap into the system. Refer to Approximate Fluid Capacities [1][2]Capacity Specifications.
30. Inspect the concentration of the coolant mixture using GE-26568 - Coolant and Battery Fluid tester.
31. Inspect the CAC cooling system for leaks.
32. Remove the absorbent rags.
33. Rinse away any excess coolant from the engine and the engine compartment.
34. Orientate the CAC quick connect fitting to the previously installed position to allow for engine cover clearance.
35. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement - Front Intake Manifold Cover Replacement - Front.
36. Install the lower radiator air inlet duct. Refer to Radiator Air Inlet Duct Replacement Radiator Air Inlet Duct ReplacementRadiator Air Inlet Duct Replacement (LSA) Radiator Air Inlet Duct Replacement.