Cooling System Draining and Filling 9C1, 9C3 Static Fill

Special Tools

J 26568 Coolant and Battery Tester

Draining Procedure

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: Draining the cooling system with the pressure cap installed will syphon the coolant from the overflow tank.

1. Remove the coolant pressure cap.
2. Place a drain pan under the drain cock.
3. Open the radiator drain cock.
4. Drain the cooling system.
5. If a complete engine block drain is required, remove the coolant drain plugs from the engine block. Refer to Draining Fluids and Oil Filter Removal.
6. Inspect the coolant.
7. 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.

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.

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.

1. Close the radiator drain cock.
2. If a complete engine block drain was required, install the coolant drain plugs to the engine block. Refer to Draining Fluids and Oil Filter Removal.



3. Remove the vent cap from the top right side of the radiator.

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

4. Slowly fill the cooling system with a 50/50 coolant mixture until the coolant comes out of the radiator vent. Refer to Approximate Fluid Capacities.
5. Install the vent cap to the top right side of the radiator.
6. Slowly fill the cooling system with a 50/50 coolant mixture until the coolant level is visible and stable at the fill neck.
7. Install the pressure cap loosely, threaded on about one turn.
8. Start the engine and raise the engine speed to 2500 RPM and hold it there for 40 seconds, then shut engine off.
9. Remove the pressure cap and fill the coolant system until the level is visible and stable.
10. Install the pressure cap loosely, threaded on about one turn.
11. Start the engine and raise the engine speed to 2500 RPM and hold it there for 30 seconds, then shut engine off.
12. Remove the pressure cap and radiator vent cap, fill the coolant system until the coolant comes out of the radiator vent.
13. Install the radiator vent cap.
14. Install the pressure cap loosely, threaded on about one turn.
15. Start the engine and raise the engine speed to 2500 RPM and hold it there for 20 seconds, then shut engine off.
16. Remove the pressure cap and fill the coolant system until the level is visible and stable.
17. Install the pressure cap, fully threaded on.
18. Fill the coolant recovery bottle to the indicator line, then add 400 milliliters (13.5 ounces) more.
19. Start the engine and run it above 2500 RPM until it is hot enough to open the thermostat, this will allow the trapped air to be purged from the engine.
20. Complete a series of three, 4 second-duration idles with 4 second-duration 3000 RPM cycles.
21. Turn the engine off and allow it to cool down to room temperature.
22. Fill the coolant recovery bottle to the indicator line.
23. Inspect the concentration of the engine coolant using the J 26568 .
24. Rinse away any excess coolant from the engine and the engine compartment.

Cooling System Draining and Filling LZE, LZ4, LZG, 9C1, 9C3, GE47716 Fill

Tools Required

Draining Procedure

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: Draining the cooling system with the pressure cap installed will syphon the coolant from the overflow tank.

1. Remove the coolant pressure cap.
2. Place a drain pan under the drain cock.
3. Open the radiator drain cock.
4. Drain the cooling system.
5. If a complete engine block drain is required, remove the coolant drain plugs from the engine block. Refer to Draining Fluids and Oil Filter Removal for the 3.5L engine or to Draining Fluids and Oil Filter Removal for the 3.9L engine.
6. Inspect the coolant.
7. 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.

Vac-N-Fill Procedure

1. If a complete engine block drain was required, install the coolant drain plugs to the engine block. Refer to Draining Fluids and Oil Filter Removal for the 3.5L engine or to Draining Fluids and Oil Filter Removal for the 3.9L engine.

Important: To prevent 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.

2. Install the J 42401 to the coolant fill port.



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



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



5. 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.
6. Pour the coolant mixture into the graduated reservoir.
7. 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.

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



9. Attach the venturi assembly to the vacuum tank.



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

Ensure the valve on the venturi assembly is closed.




11. Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.



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 and 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.




Important: Complete 2 vacuum pulls to sufficiently fill the cooling system.

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

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. Fill the coolant recovery bottle to the indicator line, then add 400 milliliters (13.5 ounces) more.
29. Install the coolant pressure cap.
30. 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.
31. Start the engine and run it above 2500 RPM until it is hot enough to open the thermostat, this will allow the trapped air to be purged from the engine.
32. Turn the engine off and allow it to cool down to room temperature.
33. Fill the coolant recovery bottle to the indicator line.

Cooling System Draining and Filling LZE, LZ4, LZG, Static Fill

Tools Required

J 26568 Coolant and Battery Tester

Draining Procedure

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: Draining the cooling system with the pressure cap installed will syphon the coolant from the overflow tank.

1. Remove the coolant pressure cap.
2. Place a drain pan under the drain cock.
3. Open the radiator drain cock.
4. Drain the cooling system.
5. If a complete engine block drain is required, remove the coolant drain plugs from the engine block. Refer to Draining Fluids and Oil Filter Removal for the 3.5L engine or to Draining Fluids and Oil Filter Removal for the 3.9L engine.
6. Inspect the coolant.
7. 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.

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.

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.

1. Close the radiator drain cock.
2. If a complete engine block drain was required, install the coolant drain plugs to the engine block. Refer to Draining Fluids and Oil Filter Removal for the 3.5L engine or to Draining Fluids and Oil Filter Removal for the 3.9L engine.

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

3. Slowly fill the cooling system with a 50/50 coolant mixture until the coolant level is visible and stable. Refer to Approximate Fluid Capacities.
4. Install the pressure cap loosely (threaded on about one turn).
5. Start the engine and raise the engine speed to 2500 RPM and hold it there for 40 seconds, then shut engine off.
6. Remove the pressure cap and fill the coolant system until the level is visible and stable.
7. Install the pressure cap loosely (threaded on about one turn).
8. Start the engine and raise the engine speed to 2500 RPM and hold it there for 30 seconds, then shut engine off.
9. Remove the pressure cap and fill the coolant system until the level is visible and stable.
10. Install the pressure cap loosely (threaded on about one turn).
11. Start the engine and raise the engine speed to 2500 RPM and hold it there for 20 seconds, then shut engine off.
12. Remove the pressure cap and fill the coolant system until the level is visible and stable.
13. Install the pressure cap, fully threaded on.
14. Fill the coolant recovery bottle to the indicator line, then add 400 milliliters (13.5 ounces) more.
15. Start the engine and run it above 2500 RPM until it is hot enough to open the thermostat, this will allow the trapped air to be purged from the engine.
16. Complete a series of three, 4-second-duration idles with 4-second-duration 3000 RPM cycles.
17. Turn the engine off and allow it to cool down to room temperature.
18. Fill the coolant recovery bottle to the indicator line.
19. Inspect the concentration of the engine coolant using the J 26568 .
20. Rinse away any excess coolant from the engine and the engine compartment.

Cooling System Draining and Filling LS4GE 47716 Fill

Tools Required

Draining Procedure

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: Draining the cooling system with the pressure cap installed will syphon the coolant from the overflow tank.

1. Remove the coolant pressure cap.
2. Place a drain pan under the drain cock.
3. Open the radiator drain cock.
4. Drain the cooling system.
5. If a complete engine block drain is required, remove the engine block drain plugs. Refer to Draining Fluids and Oil Filter Removal.
6. Inspect the coolant.
7. 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.

Vac-N-Fill Procedure

1. If a complete engine block drain was required, install the engine block drain plugs. Refer to Draining Fluids and Oil Filter Removal.

Important: To prevent 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.

2. Install the J 42401 to the coolant fill port.



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



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



5. 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.
6. Pour the coolant mixture into the graduated reservoir.
7. 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.

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



9. Attach the venturi assembly to the vacuum tank.



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

Ensure the valve on the venturi assembly is closed.




11. Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.



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 and 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.




Important: Complete 2 vacuum pulls to sufficiently fill the cooling system.

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

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. Fill the coolant recovery bottle to the indicator line, then add 400 milliliters (13.5 ounces) more.
30. Install the coolant pressure cap.
31. Start the engine and run it above 2500 RPM until it is hot enough to open the thermostat.
32. Complete a series of 3, 4-second-duration idles with 4-second-duration 3,000 RPM cycles.
33. Turn the engine OFF and allow it to cool down to room temperature.
34. Ensure the coolant recovery bottle is filled to the indicator line or above.

Cooling System Draining and Filling LS4 Static Fill

Tools Required

J 26568 Coolant and Battery Tester

Draining Procedure

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: Draining the cooling system with the pressure cap installed will syphon the coolant from the overflow tank.

1. Remove the coolant pressure cap.
2. Place a drain pan under the drain cock.
3. Open the radiator drain cock.
4. Drain the cooling system.
5. If a complete engine block drain is required, remove the coolant drain plugs from the engine block. Refer to Draining Fluids and Oil Filter Removal.
6. Inspect the coolant.
7. 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.

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.

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.

1. Close the radiator drain cock.
2. If a complete engine block drain was required, install the coolant drain plugs to the engine block. Refer to Draining Fluids and Oil Filter Removal.

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

3. Slowly fill the cooling system with a 50/50 coolant mixture until the coolant level is visible and stable. Refer to Approximate Fluid Capacities.
4. Install the pressure cap loosely (threaded on about one turn).
5. Start the engine and raise the engine speed to 2,500 RPM and hold it there for 40 seconds, then shut engine off.
6. Remove the pressure cap and fill the coolant system until the level is visible and stable.
7. Install the pressure cap loosely (threaded on about one turn).
8. Start the engine and raise the engine speed to 2,500 RPM and hold it there for 30 seconds, then shut engine off.
9. Remove the pressure cap and fill the coolant system until the level is visible and stable.
10. Install the pressure cap loosely (threaded on about one turn).
11. Start the engine and raise the engine speed to 2,500 RPM and hold it there for 20 seconds, then shut engine off.
12. Remove the pressure cap and fill the coolant system until the level is visible and stable.
13. Install the pressure cap, fully threaded on.
14. Fill the coolant recovery bottle to the indicator line, then add 400  milliliters (13.5  ounces) more.
15. Start the engine and run it above 2500 RPM until it is hot enough to open the thermostat, this will allow the trapped air to be purged from the engine.
16. Complete a series of three, four-second-duration idles with four-second-duration 3000 RPM cycles.
17. Turn the engine off and allow it to cool down.
18. Fill the coolant recovery bottle to the indicator line.
19. Inspect the concentration of the engine coolant using the J 26568 .
20. Rinse away any excess coolant from the engine and the engine compartment.