0392599 JOHNSON CARB ASSY., Lower, 140

Drain the Cooling System
Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained.
Loosen the cooling system filler cap slowly to relieve any pressure. Remove the cooling system filler cap.
Illustration 1 g06361164
Locations of the cooling system drain plugs
(1) Engine oil cooler drain
(2) Engine oil cooler drain
(3) Jacket water pump drain
Open the cooling system drain valves (if equipped). If the cooling system is not equipped with drain valves, remove drain plugs (1), (2), (3). Allow the coolant to drain.
Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant, consult your Cat dealer or Cat Dealer Service Tools Group:Outside Illinois 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
Clean the Cooling System
After the cooling system has been drained, flush the cooling system with clean water to remove any debris.
Close the cooling system drain valves (if equipped). Clean the drain plugs and install the drain plugs.
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Fill the cooling system with clean water. Install the cooling system filler cap. Operate the engine until the temperature reaches 49 °C (120 °F) to 66 °C (150 °F).
Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. Loosen the cooling system filler cap slowly to relieve any pressure. Remove the cooling system filler cap.
Open the cooling system drain valves (if equipped). If the cooling system is not equipped with drain valves, remove drain plugs (1) and (2). Allow the coolant to drain. Flush the cooling system with clean water. Close the cooling system drain valves (if equipped). Install the drain plugs.
Repeat Steps 3,4, and 5.Fill the Cooling System
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Fill the cooling system with Extended Life Coolant (ELC). See the Operation and Maintenance Manual, "Refill Capacities and Recommendations" for the correct cooling system capacity. Do not install the cooling system filler cap.
Start the engine. Operate the engine to purge the air from the cavities of the engine block. Allow the ELC to warm and allow the coolant level to stabilize. Stop the engine.
Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant within 13 mm (0.5 inch) below the bottom of the filler pipe.
Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filler cap are damaged, discard the old cap and install a new cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump to pressure test the cap. The correct pressure is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not maintain the correct pressure, install a new cooling system filler cap.
Start the engine. Inspect the cooling system for leaks and for proper operating temperature.