Cooling System Draining and Filling Static Fill

Tools Required

Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

Important: Do not use coolant system sealers in this cooling system.

1. Park the vehicle on a level surface.
2. Remove the surge tank cap.
3. Remove the air box. Refer to Air Cleaner Assembly Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the air deflector. Refer to Front Air Deflector Replacement .
6. Lower the vehicle.
7. Place a drain pan under the lower radiator hose connection.
8. Using the J 38185 reposition the lower radiator hose clamp away from the radiator.
9. Slowly remove the lower radiator hose. Drain the coolant into the drain pan.
10. Inspect the engine coolant for the following conditions:

•	Discolored appearance--Follow the flush procedure. Refer to Flushing .

•	Normal in appearance--Follow the filling procedure.

Notice: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.

1. Install the lower radiator hose.
2. Using the J 38185 reposition the lower radiator hose clamp to the radiator.
3. Lower the vehicle.
4. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system through the top of the surge tank opening. Refer to Approximate Fluid Capacities .
5. Fill the surge tank to the FULL COLD level.
6. Install the surge tank cap.
7. Idle the engine for 2 minutes and occasionally raise the throttle to 3,000-3,500 RPM.
8. Turn off the engine and allow the engine to cool.
9. Repeat the steps 3-7.
10. Install the air deflector. Refer to Front Air Deflector Replacement .
11. Install the air box. Refer to Air Cleaner Assembly Replacement .
12. Allow the engine to cool.
13. Remove the surge tank cap and fill to the FULL COLD level.
14. Use the J 26568 to inspect the concentration of the engine coolant.
15. Rinse away any excess coolant from the engine and the engine compartment.

Cooling System Draining and Filling Vac-N-Fill

Tools Required

Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

Important: Do not use coolant system sealers in this cooling system.

1. Park the vehicle on a level surface.
2. Remove the surge tank cap.
3. Remove the air box. Refer to Air Cleaner Assembly Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the air deflector. Refer to Front Air Deflector Replacement .
6. Lower the vehicle.
7. Place a drain pan under the lower radiator hose connection.
8. Using the J 38185 reposition the lower radiator hose clamp away from the radiator.
9. Slowly remove the lower radiator hose and drain the coolant into the drain pan.
10. Inspect the engine coolant for the following conditions:

•	Discolored appearance--Follow the flush procedure. Refer to Flushing .

•	Normal in appearance--Follow the filling procedure.

Important: To prevent the boiling of the coolant/water mixture in the vehicle's cooling system, do not apply vacuum to a cooling system above 49°C (120°F). The tool will not operate properly when the coolant is boiling

1. Install the J 42401 onto the coolant surge tank.



2. Attach the Vac N Fill cap to the vehicle's coolant fill port.



3. Attach the vacuum gage assembly to the Vac N Fill cap.



4. Attach the fill hose to the barb fitting on the vacuum gage assembly.

Ensure that the valve is closed.





Important: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.

Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.
5. Pour the coolant mixture into the graduated reservoir.
6. Place the fill hose in the graduated reservoir.

Important: Prior to installing the vacuum tank onto the graduated reservoir, ensure that the drain valve located on the bottom of the tank is closed.

7. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.



8. Attach the venturi assembly to the vacuum tank.



9. Attach a shop air hose to the venturi assembly.

Ensure the valve on the venturi assembly is closed.




10. Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.
11. Clamp the overflow hose closed.



12. Open the valve on the venturi assembly. The vacuum gage will begin to rise and a hissing noise will be present.



13. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg).

Cooling hoses may start to collapse. This is normal due to vacuum draw.

14. To aid in the fill process, position the graduated reservoir above the coolant fill port.



15. Slowly open the valve on the vacuum gage assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
16. Close the valve on the venturi assembly.
17. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum. Monitor for vacuum loss.

If vacuum loss is observed, refer to Loss of Coolant .

18. Open the valve on the vacuum gage assembly. The vacuum gage will drop as coolant is drawn into the system.



19. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 12-18.
20. Detach the Vac N Fill cap from the vehicle's coolant fill port.
21. Remove the J 42401 from the coolant surge tank.
22. Add coolant to the system as necessary.
23. Use the J 26568 to inspect the concentration of the coolant mixture using .

Important: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.

24. Detach the vacuum hose from the vacuum gage assembly.



25. Attach the extraction hose to the vacuum hose.



26. Open the valve on the venturi assembly to start a vacuum draw.



27. Use the extraction hose to draw out coolant to the proper level.
28. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.
29. Install the surge tank cap.