sound) is relieved, then press down on
the cap and continue turning it counter-
clockwise.
1.2 When the cap is removed, run the engine
until the upper radiator hose is hot—this
shows that the thermostat is open and
the coolant is flowing through the system.
WARNING
Use extreme care when draining coolant that is
very warm. It may still be hot enough to cause se-
rious personal injury by scalding.
1.3 Stop the engine. Remove the lower radia-
tor hose to drain the coolant. Drainage
may be speeded by removing the plug in
the bottom of the water inlet.
2. Flush the cooling system, as follows.
NOTICE
During filling, air must be vented from the engine
coolant passages. Any air trapped in the system
can cause severe engine damage.
2.1 Connect the lower radiator hose and in-
stall the plug in the bottom of the water
inlet.
2.2 Open the engine venting petcock.
2.3 Add water to the surge tank until the sys-
tem is filled.
2.4 Start the engine. Run it at low idle for 10
seconds, then at high idle for 1 minute.
Return to low idle.
2.5 Close the lower petcock when a steady
stream of water is flowing from it. Don’t
let more than 1.5 quarts (1.4 L) of water
escape.
2.6 Close the upper petcock when a steady
stream of water is flowing from it. Don’t
let more than 1.5 quarts (1.4 L) of water
escape.
2.7 Repeat several times until the drained
liquid is nearly colorless.
2.8 Completely drain the system, then close
the radiator and block the drain valves.
2.9 Disconnect all hoses from the surge tank.
Remove the tank and pour out any fluid.
Scrub and clean the inside of the surge
tank with soap and water. Flush it with
clean water, then drain it. Install the surge
tank and hoses.
IMPORTANT: On vehicles with EPA07-compliant
engines, the coolant capacity varies depending
on the engine and accessory installation. After
servicing the cooling system, always verify that
the coolant level is between the MIN and MAX
lines on the surge tank.
3. Fill the cooling system, as follows.
3.1 Slowly add a 50/50 mixture of antifreeze
and water to the surge tank until the sys-
tem is filled. Refer to the engine manufac-
turer’s service literature for approved
coolants.
3.2 With the radiator cap removed, start the
engine and run it at low idle for 10 sec-
onds; then at high idle for 1 minute. Re-
turn to low idle.
3.3 Run the engine, with the radiator cap re-
moved, until the upper radiator hose is
hot. With the engine idling, add coolant to
the radiator until it is between the MIN
and MAX lines on the surge tank. Install
the radiator cap.
20–04 Mechanical Fan Drive
Gearbox Oil Change
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. Place a drain pan under the fan drive gearbox.
IMPORTANT: Label the plugs as they are re-
moved. The breather/fill plug must always be
installed in the top of the gearbox, opposite the
drain plug.
3. Remove the drain plug and breather/fill plug,
shown in Fig. 2, to begin draining the oil.
4. Remove the oil level plug. See
Fig. 2.
5. Flush the fan drive gearbox with an approved
nonflammalbe, nontoxic solvent such as:
Engine Cooling/Radiator20
Recreational Vehicle Chassis Maintenance Manual, October 201620/2
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