Coolant Replacement
NOTE:
Some coolant/water will be retained in the cylinder block if cylinder block drain plugs are not removed. When refilling cooling system after flushing, adjust coolant mix ratio to obtain a 50/50 mix. Be certain to account for approximately 51 quarts of water left in the cylinder block when drain plugs are not removed.
1. Bring engine to normal operating temperature and turn engine OFF. With cooling system under pressure, inspect cooling system hoses and clamped hose connections for leaks, excessive deterioration, or contact wear. Inspect radiator installation retention. Note any discrepancies, and proceed.
WARNING:
NEVER REMOVE COOLING SYSTEM CAP UNDER ANY CONDITIONS WHILE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE COOLING SYSTEM OR ENGINE.
WARNING:
TO AVOID BURNS FROM SCALDING COOLANT OR STEAM, USE EXTREME CARE WHEN REMOVING THE PRESSURE CAP.
2. Drain coolant as follows:
a. If radiator is still hot, carefully wrap a thick cloth around the cap and rotate slowly until pressure begins to release. Step back until the pressure is released.
b. Then rotate cap until free. Remove the cap.
c. Open radiator draincock and disconnect engine coolant return hose at coolant inlet connection on oil filter adapter to drain the coolant system.
d. Flush reservoir with clean water, drain.
e. Correct/service/replace any components found to be malfunctioning in Step 1.
Cleaning
Tools Required:
l Rotunda Battery and Anti-Freeze Tester 021-00046
To remove rust, sludge and other foreign material from the cooling system, use an appropriate cooling system flush such as Premium Cooling System Flush FIAZ-19A503-A (ESR-M14P7-A) or equivalent. Removal of such material restores cooling efficiency and avoids overheating. Always remove the thermostat prior to pressure flushing. A pulsating or reversed direction flow of flushing water will loosen sediment more quickly than a steady flow in the normal direction of coolant flow. In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation, it will be necessary to use the pressure flushing method. Various types of flushing equipment are available.
Coolant Refill
1. Refill engine cooling system as follows:
a. Close radiator draincock and install engine coolant return hose to inlet connection.
b. When refilling the cooling system, use equal parts of water and coolant as follows:
Coolant Specification: Use only a permanent-type coolant such as Premium Cooling System Fluid E2FZ-19549-AA (ESE-M97B44-A and ESE-M97B43-A) or equivalent.
Freeze protection may also be checked by using either a Rotunda Battery and Anti-Freeze Tester 021-00046 or equivalent, or a Hydrometer. A 50/50 mix of coolant concentrate and water will provide approximately -37°C (-35°F) protection, and provide the necessary anti-corrosion protection.
Fill cooling system as outlined in this Section.