Cooling System Draining and Filling Static Fill

Tools Required

J 26568 Coolant and Battery Tester

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.

1. Remove the coolant pressure cap.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Place a drain pan under the drain cock.
4. Remove the radiator drain cock.
5. Drain the cooling system.
6. Lower the vehicle.
7. Inspect the coolant.
8. Follow the appropriate procedure based on the condition of the coolant.

•	Normal in appearance--Follow the filling procedure.

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

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

1. Raise and support the vehicle.

Important: Inspect the drain cock O-ring for signs of cracks or damage. Replace, if necessary.

2. Lubricate the drain cock O-ring with clean coolant prior to installation.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the radiator drain cock.

Tighten
Tighten the radiator drain cock to 2 N·m (18 lb in).

4. Lower the vehicle.




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

5. Slowly fill the surge tank with a 50/50 coolant mixture until the coolant level reaches the base of the surge tank fill neck. Refer to Approximate Fluid Capacities .

Important: Monitor the surge tank coolant level closely. The surge tank coolant level will begin to decrease once the engine is started.

6. Start the engine and allow to the engine to idle.

Allow the engine to idle for approximately 4 minutes.

7. Slowly fill the coolant mixture until the level stabilizes at the base of the surge tank fill neck.
8. Run the engine between 2,000-2,500 RPM for approximately 2 minutes.
9. Allow engine to idle and add approximately 1 liter (1.1 quarts) of coolant to the surge tank.
10. Install the coolant pressure cap.
11. Turn the engine OFF.
12. Allow the engine to cool.
13. Top off the coolant as necessary.
14. Inspect the concentration of the engine coolant. Using the J 26568 .
15. Rinse away any excess coolant from the engine and the engine compartment.
16. Inspect the cooling system for leaks.

Cooling System Draining and Filling GE 47716

Tools Required

Caution: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

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.

1. Remove the coolant pressure cap.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Place a drain pan under the drain cock.
4. Remove the radiator drain cock.
5. Drain the cooling system.
6. Lower the vehicle.
7. Inspect the coolant.
8. Follow the appropriate procedure based on the condition of the coolant.

•	Normal in appearance--Follow the filling procedure.

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

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

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.




2. Attach the Vac N Fill cap to the J 42401 .



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



12. 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.

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



14. 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.
15. Close the valve on the venturi assembly.
16. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss.

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

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



18. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 11-17.
19. Detach the Vac N Fill cap from the J 42401 .
20. Remove the J 42401 from the coolant surge tank.
21. Add coolant to the system as necessary.
22. Inspect the concentration of the coolant mixture using J 26568 .

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

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



24. Attach the extraction hose to the vacuum hose.



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



26. Use the extraction hose to draw out coolant to the proper level.
27. 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.
28. Install the surge tank cap.