Cooling System Draining and Filling Static Fill

Special Tools

Warning: 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.

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

1. Park the vehicle on a level surface.
2. Allow the engine to cool.
3. Remove the radiator cap.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the engine shield. Refer to Engine Shield Replacement.
6. Place a drain pan under the lower radiator hose connection at the bottom of the radiator.
7. Using J 38185 slide the hose clamp back on the lower radiator hose.
8. Slowly remove the lower radiator hose and drain the coolant into the drain pan.
9. Inspect the engine coolant for the following:

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

•	Normal in appearance - follow the filling procedure.

•	If a complete block drain is required, remove the coolant heater located on the LH side of the block. Refer to Coolant Heater Replacement.

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

1. If a complete block drain was required, install the coolant heater. Refer to Coolant Heater Replacement.
2. Install the lower radiator hose.
3. Using the J 38185 slide the lower radiator hose clamp into the original position.
4. Lower the vehicle.

Note: Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system through the top of the radiator until full. Refer to Approximate Fluid Capacities.

5. Install the radiator cap.
6. Remove coolant recovery reservoir cap.
7. Fill the coolant recovery reservoir with the remaining coolant.
8. Install coolant recovery reservoir cap.
9. Start the engine.
10. Run the engine at 2,000-2,500 RPM until the engine reaches normal operating temperature.
11. Allow the engine to idle for 3 minutes.
12. Shut the engine off.
13. Allow the engine to cool.
14. Top off the coolant recovery reservoir as necessary.
15. Inspect the cooling system for leaks.
16. Rinse away any excess coolant from the engine and the engine compartment.
17. Inspect the concentration of the engine coolant using J 26568 .

Cooling System Draining and Filling Vac-N-Fill

Special Tools

Warning: 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.

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

1. Park the vehicle on a level surface.
2. Allow the engine to cool.
3. Remove the radiator cap.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Place a drain pan under the lower radiator hose connection at the bottom of the radiator.
6. Using J 38185 slide the hose clamp back on the lower radiator hose.
7. Slowly remove the lower radiator hose and drain the coolant into the drain pan.
8. Inspect the engine coolant for the following:

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

•	Normal in appearance--Follow the filling procedure.

•	If a complete block drain is required, remove the coolant heater located on the LH side of the block. Refer to Coolant Heater Replacement.

Note: 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 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.





Note: 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.

Note: 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 gage assembly and the vacuum tank.
11. Clamp off the overflow hose.



12. Open the valve on the venture 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 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 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 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 .

Note: 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 gage 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.