B. Chemical Flushing Procedure
Applies to all vehicles in the VIN range 001036-005957 for which the Heater Performance Test indicates an unsatisfactory condition.Consists of the following operations:
^ Drain and discard existing coolant.
^ Flush cooling system with plain water.
^ Treat cooling system with part 1 flushing solution (blue label).
^ Flush cooling system with plain water.
^ Treat cooling system with part2 flushing solution (pink label).
^ Flush cooling system with plain water, twice.
1. Place a suitable drain pan under the radiator and remove the drain plug. Allow the coolant to drain as much as possible. Wash off any coolant spilled on the body of the vehicle.
WARNING:
The coolant will be hot.
2. Install the radiator flushing adaptor, 100-020, in place of the radiator drain plug. Connect a hose, secured with a worm-drive hose clamp (Illustration 2), to allow the radiator flushing solutions to be drained into a container. Clamp the hose shut for the next steps.
3. Lower the vehicle.
4. Place a shop rag under the coolant reservoir. Disconnect the hose that runs from the coolant reservoir to the recovery bottle.
5. Remove the air cleaner cover, MAF sensor, and the air intake duct assembly for access.
6. Clamp the heater bypass hose to prevent the flow of coolant through the hose (Illustration 3).
7. Reinstall the air cleaner cover, MAF sensor, and the air intake duct assembly.
8. Remove the thermostat housing cap. Fill the cooling system with clean water through the reservoir until the level stabilizes at the top of the thermostat housing neck. Replace the caps on the thermostat housing and coolant reservoir.
9. Start the engine. Press red arrow on the Climate Control panel repeatedly until display changes to HI. Turn the fan knob clockwise until the fan speed bar graph shows the maximum fan speed. Run the engine at approximately 2000 rpm with the transmission selector lever in P or N for 5 minutes at this setting.
10. Switch off the engine.
WARNING:
The cooling system will be pressurized and hot.
Remove the cap from the coolant reservoir.
11. Raise the vehicle. Loosen the clamp on the hose connected to the flushing adapter and drain the water from the cooling system.
WARNING:
The water will be hot.
12. Clamp the drain hose and lower the vehicle.
13. Note the contents of the radiator flushing kit, JLM 20361. Each kit contains two bottles of flushing solution, part 1 (blue label) and part 2 (pink label). Each box contains two kits to provide the required quantity for one vehicle. Select the two bottles of part 1 flushing solution.
WARNING:
Wear goggles and protective gloves when working with chemical solutions.
14. Remove the cap from the thermostat housing.
15. Use a funnel to ensure that no spillage occurs and pour the two (2) bottles of part 1 solution into the coolant reservoir.
16. Continue to fill the cooling system with clean water through the reservoir until the level stabilizes at the top of the thermostat housing neck.
17. Reinstall the reservoir and thermostat housing caps. Wash away any flushing solution that may have been spilled.
18. Start the engine. Press red arrow on the Climate Control panel repeatedly until display changes to HI. Turn the fan knob clockwise until the fan speed bar graph shows the maximum fan speed. Run the engine at approximately 2500-3000 rpm with the transmission selector lever in P or N for 30 minutes at this setting.
19. Switch off the engine.
WARNING:
The cooling system will be pressurized and hot.
Remove the cap from the coolant reservoir.
20. Raise the vehicle. Loosen the clamp on the hose connected to the flushing adapter and drain the water and flushing solution from the cooling system.
WARNING:
The water and flushing solution will be hot.
21. Clamp the drain hose and lower the vehicle.
22. Remove the thermostat housing cap. Fill the cooling system with clean water through the reservoir until the level stabilizes at the top of the thermostat housing neck. Replace the caps on the thermostat housing and coolant reservoir.
23. Start the engine. Press red arrow on the Climate Control panel repeatedly until display changes to HI. Turn the fan knob clockwise until the fan speed bar graph shows the maximum fan speed. Run the engine at approximately 2000 rpm with the transmission selector lever in P or N for 5 minutes at this setting.
24. Switch off the engine.
Remove the cap from the coolant reservoir.
25. Raise the vehicle. Loosen the clamp on the hose connected to the flushing adapter and drain the water from the cooling system.
26. Clamp the drain hose and lower the vehicle.
27. Remove the cap from the thermostat housing.
28. Use a funnel to ensure that no spillage occurs and pour the two (2) bottles of part 2 solution into the coolant reservoir.
29. Continue to fill the cooling system with clean water through the reservoir until the level stabilizes at the top of the thermostat housing neck.
30. Reinstall the reservoir and thermostat housing caps. Wash away any flushing solution that may have been spilled.
31. Start the engine. Press red arrow on the Climate Control panel repeatedly until display changes to HI. Turn the fan knob clockwise until the fan speed bar graph shows the maximum fan speed. Run the engine at approximately 2500-3000 rpm with the transmission selector lever in P or N for 15 minutes at this setting.
32. Switch off the engine.
WARNING:
The cooling system will be pressurized and hot.
Remove the cap from the coolant reservoir.
33. Raise the vehicle. Loosen the clamp on the hose connected to the flushing adapter and drain the water and flushing solution from the cooling system.
WARNING:
The water and flushing solution will be hot.
34. Clamp the drain hose and lower the vehicle.
35. Remove the thermostat housing cap. Fill the cooling system with clean water through the reservoir until the level stabilizes at the top of the thermostat housing neck. Replace the caps on the thermostat housing and coolant reservoir.
36. Start the engine. Press red arrow on the Climate Control panel repeatedly until display changes to HI. Turn the fan knob clockwise until the fan speed bar graph shows the maximum fan speed. Run the engine at approximately 1500 rpm with the transmission selector lever in P or N for 5 minutes at this setting.
37. Switch off the engine.
WARNING:
The cooling system will be pressurized and hot.
Remove the cap from the coolant reservoir.
38. Raise the vehicle. Loosen the clamp on the hose connected to the flushing adapter and drain the water from the cooling system.
WARNING:
The water will be hot.
39. Clamp the drain hose and lower the vehicle.
40. Remove the thermostat housing cap. Fill the cooling system with clean water through the reservoir until the level stabilizes at the top of the thermostat housing neck. Replace the caps on the thermostat housing and coolant reservoir.
41. Start the engine. Press red arrow on the Climate Control panel repeatedly until display changes to HI. Turn the fan knob clockwise until the fan speed bar graph shows the maximum fan speed. Run the engine at approximately 1500 rpm with the transmission selector lever in P or N for 15 seconds at this setting.
42. Switch off the engine.
WARNING:
The cooling system will be pressurized and hot.
Remove the cap from the coolant reservoir.
43. Raise the vehicle. Loosen the clamp on the hose connected to the flushing adapter and drain the water from the cooling system.
WARNING:
The water will be hot.
44. Disconnect the hose from the radiator flushing adapter tool and remove the tool.
45. Remove and discard the existing 0-ring from the radiator drain plug. Install a new 0-ring and then the drain plug.
46. Reinstall the generator cooling duct.
47. Remove the air cleaner cover, MAF sensor, and the air intake duct assembly for access.
48. Reinstall the hose that runs from the coolant reservoir to the recovery bottle. Use a new clamp if needed.
49. Remove the clamp from the heater bypass hose.
50. Reinstall the air cleaner cover, MAF sensor, and the air intake duct assembly.
51. Refill the cooling system with antifreeze/coolant. Refer to Section D REFILLING COOLING SYSTEM WITH COOLANT D542.