Cooling System Draining and Filling Static Fill

Tools Required

J 26568 Coolant and Battery Fluid 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 in General Information.
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: Refer to Fastener Notice in the Preface section.




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 cooling system with a 50/50 coolant mixture. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.
6. Install the coolant pressure cap.
7. Start the engine.
8. Run the engine at 2,000-2,500 RPM until the engine reaches normal operating temperature.
9. Allow the engine to idle for 3 minutes.
10. Shut the engine OFF.
11. Allow the engine to cool.
12. Top off the coolant as necessary.
13. Inspect the concentration of the engine coolant. Using the J 26568 .
14. Rinse away any excess coolant from the engine and the engine compartment.
15. Inspect the cooling system for leaks.

Cooling System Draining and Filling Vac-N-Fill

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. Drain the cooling system.
5. Lower the vehicle.
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 .

Important: To prevent boiling of the coolant/water mixture in the vehicles 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 .



2. Attach the Van-N-Fill cap to the vehicles coolant fill port.



3. Attach the vacuum gauge assembly to the Vac-N-Fill cap.



4. Attach the fill hose to the barb fitting on the vacuum gauge 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 venture assembly to the vacuum tank.



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

Ensure the valve on the venture assembly is closed.




10. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
11. Clamp off the overflow hose.



12. Open the valve on the venture assembly. The vacuum gauge 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 gauge 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 venture 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 gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.



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

24. Detach the vacuum hose form the vacuum gauge assembly.



25. Attach the extraction hose to the vacuum hose.



26. Open the valve on the venture 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.