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Coolant Pre-Heater Removal

Remove the coolant pre-heater as follows: ‪


To avoid injury from scalding, drain the radiator when the engine and coolant are cool.

  1. Drain the coolant from the radiator. See Figure 42454 . Cooling system capacity is listed in Table .

    Coolant Drain Plug

    Description ‪

    4-Cylinder ‪

    L (qt) ‪

    6-Cylinder ‪

    L (qt) ‪

    Total capacity ‪

    19 (20) ‪

    23 (24) ‪

    Antifreeze quantity at 50% ‪

    9.5 (10.0) ‪

    11.5 (12.0) ‪

    Antifreeze quantity at 55% ‪

    10.5 (11.1) ‪

    12.7 (13.4) ‪

    Cooling System Capacity


    To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.

    1. Open the cap on the surge tank slowly, to allow excess pressure to escape.
    2. Place a receptacle underneath the coolant drain plug. Choose one that is large enough to hold the expected quantity of coolant.

      Note: Make sure the coolant can flow unobstructed into the receptacle.

    3. Open the coolant drain plug on the bottom of the radiator.
  2. Disconnect the electrical connector from the coolant pre-heater. See Figure 42455 .

    1. Coolant Pre-heater ‪

    3. Electrical Connector ‪

    2. O-ring ‪

    Coolant Pre-Heater

  3. Remove the coolant pre-heater from the engine access hole. Discard the O-ring.

    Note: Collect any coolant that runs out of the access hole.

Coolant Pre-Heater Installation

Install the coolant pre-heater as follows: ‪

  1. Install the coolant pre-heater in the engine access hole. Replace the O-ring with a new one.
  2. Connect the electrical connector to the coolant pre-heater.
  3. Fill the engine with the coolant.
    1. Tighten the coolant drain plug on the bottom of the radiator.
    2. Add coolant up to the maximum fill level on the surge tank.
  4. Check the coolant level and check the cooling system for leaks.


    To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.


    Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

    • Always start and operate an engine in a well ventilated area.
    • If operating an engine in an enclosed area, vent the exhaust to the outside.
    • Do not modify or tamper with the exhaust system or emission control system.
    1. Start the engine and run it for about one minute at varying speeds to release air pockets in the cooling system.
    2. Check all hoses at the radiator, coolant pump, and surge tank for leaks.
    3. Check the coolant level and add more coolant if necessary.
  5. Shut down the engine.
  6. Close and tighten the cap on the surge tank.