Cooling System—Filling
CAUTION: Avoid being scalded when opening surge tank cap. Open cap 1.5 turns to relieve pressure. Never open cap when engine is hot and never fill cooling system when engine is overheated unless engine is idling slowly. Pour coolant in slowly. Check coolant level when engine is cold.
IMPORTANT: A special cap is used on the surge tank and radiator. If either cap is damaged or missing, it must be replaced by an equivalent cap.
Never pour cold water into a hot engine as it might crack cylinder block or head. Do not operate engine without coolant.
Surge Tank Fill (Routine Check)
H91168-UN-17APR08
A - Surge Tank
B - Max Cold Line
Fill surge tank (A) until fluid is at “Max Cold” line.Install cap on surge tank and radiator, turn ON heater and run engine until it reaches operating temperature.
Carefully remove cap from surge tank and refill as necessary. Install cap on surge tank and close engine access doors.
When engine is cool, coolant level should be at “Max Cold” line.
Radiator Fill (System Service/Flushing)
H87203-UN-16JAN07
A - Radiator
Fill radiator (A) until no more fluid can be added, (refer to Specifications section for Radiator Capacities).
H87197-UN-12JAN07
A - Plug
Loosen plug (A) on top of Exhaust Gas Recirculation (EGR) cooler near rear of engine (plug does not need to be removed completely).Tighten plug to specification when coolant is observed leaking from this location (cooler is now de-aerated).
| Item | Measurement | Specification |
| Plug | Torque | 20 N·m (15 lb-ft) |
After filling radiator, install cap and finish fill surge tank until coolant level is at “Max Cold” line.
Turn ON heater and run engine until it reaches operating temperature.
OUO6075,00000CA-19-20080430 |