IK1201248 ­ Cooling System Flush Procedure

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Document ID: IK1201248

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Title : Cooling System Flush Procedure
Applies To : All Engines

CHANGE LOG
2015/03/10 - Added system flush checklist, notes and warning, along with formatting.
2015/02/12 - Initial Article Release

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DESCRIPTION
In the event of an oil cooler failure, engine oil may have entered the cooling system and mixed with the engine coolant. This
document will guide the user to properly flush the contaminated cooling system. This procedure may be used on all engines,
however; for demonstration purposes this article uses a MaxxForce 13L Engine.

SYMPTOMS
Customer Observations or Concerns:
­ Contaminated cooling system
- Coolant hose swelling or softening

SPECIAL TOOLS
Tool Description

Tool Number

Comments

Instructions

Coolant Flush Adapter Kit

09­889­02

Link

Coolant Management System

KL5007NAV

Link

Cleaning Management System

12­353­01A

Link

International Reprogramming Harness

406010

SCR Equipped Only

International Electronic Engine Terminal Test
Kit

ZTSE4435C

SCR Equipped Only

Breakout Harness

ZTSE4827

SCR Equipped Only

SERVICE PARTS INFORMATION
Kit Description
Fluid, Engine System Cleaner

Part Number
2514295C91

Qty Notes
1
Two 2.5 Gal. Containers

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IK1201248 ­ Cooling System Flush Procedure

Coupling, Heat Exchanger Quick Connect

3688493C2

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1

Only if it is not Installed

REPAIR STEPS

This procedure uses the tooling (sizes) required to perform these steps on certain vehicles.
Some vehicles may require a different size tool. These tools can be found in the Coolant Flush
Adapter Kit as there are multiple sizes of the same tooling.

When draining any contaminated fluid from the system components, make sure to drain into a
drain pan, NOT the Coolant Management System (CMS).

GOVERNMENT REGULATION: Engine fluids (oil, fuel and coolant) may be hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters,
rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters
and other contaminated materials according to applicable regulations.

BEFORE BEGINNING:
Understand what components are affected by a contaminated cooling system. Review the following checklist to ensure
all components are accounted for.

System Flush Checklist

Y/N?

Engine/Radiator
Heater Core (s)
Diesel Exhaust Fluid (DEF)
Heater Hoses
Optional Heaters
Optional Auxiliary Power Unit
(APU)
Aftermarket Equipment (nonwarranty)

PREPARATION:
• Inspect coolant hoses for swelling and/or softening from oil contamination
• If cooling system is full, start engine and allow coolant temperature to reach 120°F (48.8°C), to aid in draining cooling
system contaminants.
• If cooling system is empty, fill the system with water following the proper fill procedure (IK0900017), then start engine and
allow coolant temperature to reach 120°F (48.8°C).

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Figure 1: Deaeration Tank and Pressure Module
Item 1: Pressure Module (KL5006NAV)
Item 2: Cap Adapter (KL5006NAV)
Item 3: Deaeration Tank
1. Install cap adapter (Figure 1, Item 2) and pressure module (Figure 1, Item 1) onto deaeration tank (Figure1, Item 3)

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Figure 2: Radiator Discharge Hose
Item 1: Radiator Drain Coupler
Item 2: Radiator Discharge Hose (09-146-01)
2. Connect radiator discharge hose (Figure 2, Item 2) onto radiator drain coupler (Figure 2, Item 1)

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Figure 3: Thermostat Housing
Item 1: Thermostats
Item 2: Thermostat Housing
3. Remove thermostat housing (Figure 3, Item 2) and thermostats (Figure 3, Item 1)

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Figure 4: Gasket Installation
Item 1: Gaskets (09­889­02­05
4. Install two rubber gaskets (Figure 4, Item 1) and re-install thermostat housing (Figure 3, Item 2) and radiator hoses
5. Pressurize coolant system with shop air and drain contaminated fluid from radiator into a drain pan

If contaminated fluid is too thick to drain out of radiator drain valve, remove radiator lower hose.

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Figure 5: Low-Temperature Radiator (LTR) Drain Coupler
Item 1: LTR Drain Coupler (3688493C2)

If LTR radiator drain coupler is not installed, install LTR drain coupler
6. Connect radiator discharge hose (Figure 2, Item 2) onto low-temperature radiator (LTR) drain coupler (Figure 5, Item1)
7. Pressurize coolant system with shop air and drain contaminated fluid from LTR into drain pan

Only perform steps 8 - 10 if equipped with a coolant filter

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Figure 6: Coolant Filter Assembly
Item 1: Filter Clamp Locations
Item 2: Coolant Filter Housing
Item 3: Coolant Filter
8. Remove and discard coolant filter (Figure 6, Item 3) from housing (Figure 6, Item 2) - Clean housing
9. Install fitting (09-889-02-07) into hoses and dissconnect from coolant filter
10. Vacuum fill coolant system with 2.5 gal. of Engine System Cleaner and 15 gal. of water using the Coolant Management
System (KL5007NAV)
11. Start engine and run for approximately 30 ­ 45 minutes at 1200 rpm
12. Shut down engine and REPEAT steps 5 - 11 as needed

Low Temperature Radiator (LTR) and Engine Flush

Prior to flushing, water and cleaner mixture should be heated to 115°F (46°C) minimum.
Use hot water if available.

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Figure 7: Low Temperature Radiator Tube and Coolant Control Valve Hose
Item 1: LTR Lower Tube
Item 2: Coolant Control Valve (CCV) Hose
1. Disconnect the hose illustrated above (Figure 7, Item 2) and install two small coolant flush adapters
2. Using cap (Figure 8, Item 4), cap off adapter installer on Coolant Control Valve Hose (Figure 7, Item 2)

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Figure 8: Dearation Tank
Item 1: Deareation Tank
Item 2: Deaeration Tank Adapter (09-889-02-03)
Item 3: Cleaning Management System Hose
Item 4: Cap (12-353-01-06)
3. Install Deaeration Tank Adapter (Figure 8, Item 2) onto deaeration tank (Figure 8, Item 1)
4. Connect Cleaning Management System (12-353-01A) hoses to adapters and run for approxmiately 15 minutes, flushing the
engines coolant system
5. Reverse the hoses and run Cleaning Management System (12-353-01A) for an additional 15 minutes

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Check condition of fluid, if fluid has a dark "blackish" color, empty contents and fill with
15 gallons of water and 2.5 gallons of Engine System Cleaner.

Radiator and Engine Flush

Prior to flulshing, water and cleaner mixture should be heated to 115°F (46°C) minimum. If
available, fill container with hot water.

Figure 9: Upper Radiator Hose
Item 1: Thermostat Housing Hose
Item 2: Large Coolant Flush Adapter (09-889-02-01)
1. Disconnect upper radiator hose and install both Large Coolant Flush Adapters
2. Connect Cleaning Management System (12-353-01A) hoses to adapters and flush for 15 minutes
3. Reverse the hoses and run Cleaning Management System (12-353-01A) for an additional 15 minutes

Check condition of fluid, if fluid has a dark "blackish" color, empty contents and fill with
15 gallons of water and 2.5 gallons of Engine System Cleaner.

Heater Core and DEF Hose Flush

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Prior to flushing, water and cleaner mixture should be heated to 115°F (46°C) minimum.
Use hot water if available

Figure 10: Heater Core and DEF Hoses
Item 1: Inlet Hose
Item 2: Outlet Hose
1. Disconnect Heater Core Hoses and install Small Coolant Flush Adapters
2. Connect Cleaning Management System (12-353-01A) hoses to adapters and flush for 15 minutes
3. Reverse the hoses and run Cleaning Management System (12-353-01A) for an additonal 15 Minutes
4. Repeat steps 1 thru 3 while flushing the DEF hoses and Auxillary Heater Core if applicable

Check condition of fluid, if fluid has a dark "blackish" color, empty contents and fill with
15 gallons of water and 2.5 gallons of Engine System Cleaner.

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When flushing the DEF hoses (if applicable) you will need to override the DEF Solenoid to
flush the DEF hoses completely. Please see the steps below to open the DEF Solenoid

Figure 11: DEF Solenoid Location
Item 1: Diesel Exhaust Fluid (DEF) Tank
Item 2: Diesel Exhaust Fluid Tank Heater Valve (DEFTHC)
1. Located the DEFTHC, and disconnect the electrical connection
2. Connect ZTSE4827 (breakout harness), leave harness side disconnected

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Figure 12: ECM Programming Harness (406010)
Item 1: Positive Cable Hookup
Item 2: Ground Cable Hookup
Item 3: 12 Volt Supply
3. Hook up 406010 using terminal kit ZTSE4435C

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Figure 13: ECM Programming Harness
Item 1: Diesel Exhaust Fluid Tank Heater Valve (DEFTHC)
Item 2: ZTSE4827 (breakout harness)
Item 3: Power/Signal from 12 volt supply
4. When hooking up jumpers, power (coming from 12volt supply box) will be #1 on the ZTSE4827 breakout harness and ground
will be #4 on the breakout harness
5. When ready to flush the DEF Lines, switch the 12 volt supply switch to the ON position.

Final Rinse
1. Ensure all hoses are connected and backfill cooling system with water using appropriate fill procedure found in IK0900017
2. Start engine and run for approximatley 30 ­ 45 minutes at 1200 rpm
3. Shut down engine and drain (repeat steps 1 - 3 as needed until clear fluid comes out)

If there are still traces of oil left in the cooling system, replace all rubber hoses for cooling
system as they may soaked with oil and repeat flushing procedures as necessary.
4. Remove rubber gaskets by removing the thermostat housing
5. Replace the thermostats using new parts
6. Re-connect all loose hoses and connections
7. Use cooling system fill procedure outlined in IK0900017 and fill with appropriate coolant

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WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engine
Noun: 686 - Cooler, Oil
Standard Repair Time(s):
Description
Cooling System, Flush
Cooling System, Flush

Chassis
SRT
ProStar Sleeper R09-1022U-21
ProStar Daycab R09-1022U-22

Hours
9.8
9.1

Cooling System, Flush

7600

N09-1022U-21

9.1

Cooling System, Flush
Cooling System, Flush

Transtar
5000

Q09-1022U-21
T09-1022U-21

9.1
9.1

Cooling System, Flush

CAT CT660

TC09-1022U-21

9.1

OTHER RESOURCES
Master Service Information Site
MaxxForce® 11 and 13 Engine Diagnostic Manual (EPA 10, HD-OBD) Revision 8 (Supersedes EGES-470)
MaxxForce® 11 and 13 Engine Service Manual (EPA 10), Revision 6, (Supersedes EGES-465)
MaxxForce® 11 and 13 (EPA 07) Engine Diagnostic Manual (Revision 2)
MaxxForce® 11 and 13 (EPA 07) Engine Service Manual (Revision 2)

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