Charge Air Cooling System Draining and Filling Static

Special Tools

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
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

Caution: Refer to Fastener Caution in the Preface section.




9. Install the charge air cooler radiator drain plug (1) and tighten to 1.5 N·m (13 lb in).
10. Install the front air deflector. Refer to Front Air Deflector Replacement
11. Lower the vehicle.

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



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
4. Install the bleeder screw (1) and tighten to 1.5 N·m (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
21. Rinse away any excess coolant from the engine and the engine compartment.

Charge Air Cooling System Draining and Filling GE 47716

Special Tools

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
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

Caution: Refer to Fastener Caution in the Preface section.

9. Install the charge air cooler radiator drain plug (1) and tighten to 1.5 N·m (13 lb in).
10. Install the front air deflector. Refer to Front Air Deflector Replacement
11. Lower the vehicle.

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 gage assembly to the Vac N Fill cap.



4. Attach the fill hose to the barb fitting on the vacuum gage 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 gage assembly and the vacuum tank.



11. Open the valve on the venturi assembly. The vacuum gage 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 gage 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.

17. Open the valve on the vacuum gage assembly. The vacuum gage will drop as coolant is drawn into the system.



18. Once the vacuum gage reaches zero, close the valve on the vacuum gage 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 gage 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.