Drain, Flush, and Refill Cooling System—5000 Hours or Five Years

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove cap when cool enough to touch with bare hands.

IMPORTANT:

TS281-UN-15APR13

1. Remove radiator reservoir tank cap.

2. Turn key to Run, then turn temperature knob to highest setting.

3. NOTE: Right-hand side shown, left-hand side the same.

   
   N99443-UN-14AUG12

   A - Cap Screw (5 used)

   B - Front Engine Panel

   Remove cap screws (A) and left- and right-hand front engine panels (B).

---




4. 
   N99436-UN-10AUG12

   A - Cap Screws (3 used)

   Remove cap screws (A) and remove fan guard.

---




5. 
   N100724-UN-22OCT12

   A - Cap Screw (4 used)

   Remove cap screws (A) and shield.

---




6. NOTE: Approximate capacity of cooling system is 38 L (10 gal.).

   
   N90579-UN-29NOV10

   A - Drain Valve

   Open radiator drain valve (A). Drain coolant into an approved container.

---




7. Disconnect harness connectors from radiator de-aeration tank.

8. 
   N100728-UN-22OCT12

   A - Clamp

   B - Clamp

   C - Clamp

   D - Clamp

   E - Cap Screw (2 used)

   Remove clamps (A—D) and hoses.

---




9. Remove cap screws (E) and radiator de-aeration tank.

10. 
    N100730-UN-22OCT12

    A - Nut (2 used)

    B - Cap Screw (6 used)

    C - Radiator Support

    Remove cap screws (B), nuts (A), and radiator support (C).

---




11. 
    N99762-UN-30AUG12

    A - Fitting

    B - Cap Screw (4 used)

    Remove fitting (A), caps screws (B), and front hood support.

---




12. 
    N100729-UN-22OCT12

    A - Cap Screw (4 used)

    B - Hose

    C - Fittings (2 used)

    D - Line

    Remove fittings (C) and set hose (B) and line (D) aside.

---




13. Remove cap screws (A) and thermostat housing.

14. Remove old thermostat and clean sealing area.

15. Apply RTV silicone sealant to new gasket.

16. Install new thermostat, new gasket, and cover.

17. Assemble in reverse order.

18. Close radiator drain valve.

19. IMPORTANT: Never pour cold water or coolant into hot engine.

    Fill radiator with cooling system cleaning solution.

20. Install radiator reservoir cap, install front side panels, and close hood.

    CAUTION: Make sure that side panel is installed and hood is closed before starting engine.

21. Start engine and run at a minimum of 1500 rpm for 15 minutes.

    CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

    
    TS281-UN-15APR13

    Shut off engine. Only remove cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

---




22. Shut off engine and allow cleaning solution to cool.

23. Open hood, remove radiator reservoir cap. Open radiator drain valve. Drain solution into an approved container.

24. Close radiator drain valve.

25. IMPORTANT: Never pour cold water or coolant into hot engine.

    Fill radiator with clean water.

    CAUTION: Make sure that hood is closed before starting engine.

26. Install radiator reservoir cap and close hood. Start engine and run for a minimum of 1500 rpm for 15 minutes.

27. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

    Shut off engine. Only remove cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

    Turn off engine, allow clean water to cool.

28. Open hood, remove radiator reservoir cap. Open radiator drain valve. Drain water into an approved container.

29. Close radiator drain valve.

30. Fill radiator with coolant.

    CAUTION: Make sure that hood is closed before starting engine.

    NOTE: Coolant leaking on ground indicates air in high-pressure circuit is being discharged.

31. Install radiator reservoir cap and close hood, start engine and run for a minimum of 1500 rpm for 15 minutes.

32. NOTE: Level may change when engine is running or during next few cycles.

    Monitor coolant level for next several hours/overnight. Refill radiator reservoir tank as required.