Cooling System Draining and Filling 2.0L (LSJ)

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 surge tank cap.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Place a drain pan under the right side of the lower radiator mount.



4. Open the radiator drain cock.
5. Drain the cooling system.



6. If a complete block drain is required, place a drain pan under the water pump drain.
7. Remove the water pump drain plug (1).
8. Drain the cooling system.
9. Inspect the appearance of the engine coolant for discoloration:

•	Discolored--Follow the flush procedure. Refer to Coolant System 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. Close the radiator drain cock by hand.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the water pump drain plug (1) if the plug was removed during the draining process.

Tighten
Tighten the plug to 22 N·m (16 lb in).

3. Lower the vehicle.



4. Remove the upper radiator inlet hose from the passenger side radiator.

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

5. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the engine through the upper radiator hose.
6. Install the upper radiator inlet hose to the radiator.



7. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system until the coolant reaches and maintains a level slightly above the cold fill line on the surge tank. Refer to Approximate Fluid Capacities .
8. Install surge tank cap.
9. Start the engine.
10. Run the engine at 2,000-2,500 RPM for 3 minutes.
11. Allow the engine to idle for 30 seconds.
12. Shut the engine OFF.
13. Top off the coolant as necessary.
14. Inspect the cooling system for leaks.
15. Rinse away any excess coolant from the engine and the engine compartment.

Cooling System Draining and Filling Static Fill LE5, L61

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 surge tank cap.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Place a drain pan under the right side lower radiator mount.



4. Open the radiator drain cock.
5. Drain the cooling system.



6. If a complete block drain is required, place a drain pan under the water pump drain.
7. Remove the water pump drain plug (1).
8. Drain the cooling system.
9. Inspect the appearance of the engine coolant for discoloration:

•	Discolored--Follow the flush procedure. Refer to Coolant System 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. Close the radiator drain cock by hand.

Notice: Refer to Fastener Notice in the Preface section.




2. Install the water pump drain plug (1) if removed during the draining process.

Tighten
Tighten the plug to 22 N·m (16 lb in).

3. Lower the vehicle.

Important: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water. It is necessary to maintain the coolant level near the cold fill line on the surge tank to insure all the air has been purged from the cooling system.

4. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system until the coolant level reaches and maintains slightly above the cold fill line on the surge tank. Refer to Approximate Fluid Capacities.



5. Install surge tank cap.
6. Start the engine.
7. Run the engine at 2,000-2,500 RPM for 3 minutes.
8. Allow the engine to idle for 30 seconds.
9. Shut the engine off.
10. Top off the coolant as necessary.
11. Inspect the cooling system for leaks.
12. Rinse away any excess coolant from the engine and the engine compartment.

Cooling System Draining and Filling GE 47716 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 pressure cap.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Place a drain pan under the right side lower radiator mount.



4. Open the radiator drain cock.
5. Drain the cooling system.



6. If a complete block drain is required, place a drain pan under the water pump drain.
7. Remove the water pump drain plug (1).
8. Drain the cooling system.
9. Inspect the appearance of the engine coolant for discoloration:

•	Discolored--Follow the flush procedure. Refer to Coolant System 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. Close the radiator drain cock by hand.




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 J-42401-2 into the surge tank fill neck.
3. Install J-42401-3 to the surge tank fill neck.
4. Attach the Vac N Fill cap to the J-42401-3.



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



6. 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.
7. Pour the coolant mixture into the graduated reservoir.
8. 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.

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



10. Attach the venturi assembly to the vacuum tank.



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

Ensure the valve on the venturi assembly is closed.




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



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



14. 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.

15. To aid in the fill process, position the graduated reservoir above the surge tank.



16. 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.
17. Close the valve on the venturi assembly.
18. 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.

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



20. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 10-16.
21. Detach the Vac N Fill cap from the vehicle's 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 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.