CAUTION: Remove caps only when coolant temperature is below boiling point. First loosen the black cap (B) to relieve pressure, then remove the green cap (C) completely.

NOTE: If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

1. Place a container under the drains to trap the coolant as it emerges.

2. Turn heater switch fully to the right.

3. Remove right fan guard and open radiator drain cock (A).

4. Remove expansion tank filler cap (C).

5. Remove drain plug (D) from engine block.

6. Remove thermostat housing (E) and take out thermostat. Re-install the housing without the thermostat, and tighten the screws again.

IMPORTANT: The thermostat must be removed to ensure that the system is fully drained.

As soon as system is empty, close radiator drain cock (A), screw in drain plug (D) and fill the system with clean water.

Run engine again until it reaches operating temperature. Shut off engine and drain cooling system.

Close drain cock again and fill the system with clean water.

IMPORTANT: Never pour cold water or coolant into the hot engine. Always use warm water or wait until engine has cooled down.

Again run engine until it has reached operating temperature. Shut off engine and drain system again.

Check the thermostat as described on the next page.

Take off the thermostat housing and clean the sealing surface. Apply sealant to a new gasket. Install gasket and new (or checked) thermostat. Tighten the screws to 48 N·m (35 lb-ft).

Close drain cock again, and this time fill the system with the specified coolant (see section "Fuel, Lubricants, Hydraulic Oil and Coolant").

Run the engine until it reaches operating temperature. This will allow the thermostat to open, ensuring that coolant is circulated throughout the entire cooling system.

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Recheck coolant level. It should be between the "min" and "max" marks on the expansion tank.

For efficient cooling, the radiator screen must be kept clean. Remove any dust or oil and carefully straighten any bent fins.

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