GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 General Information 🢒 General Information 🢒 Cooling System Draining and Filling

Draining Procedure

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.


    Object Number: 873722 Size: SH
  1. Remove the surge tank cap.
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Place a drain pan under the right side lower radiator mount.

    4. Object Number: 877653 Size: SH
  4. Open the radiator drain cock.
  5. Drain the cooling system.

    6. Object Number: 893494 Size: SH
  6. If a complete block drain is required, place a drain pan under the water pump drain.
  7. Open the water pump drain plug (1).
  8. Drain the cooling system.
  9. Inspect the engine coolant for the following:
    10. • Discolored -- follow the flush procedure. Refer to Coolant System Flushing .
    • Normal in appearance -- follow the filling procedure.

Filling Procedure

    Object Number: 877653 Size: SH
  1. Close the radiator drain cock by hand.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 893494 Size: SH
  2. Install the water pump drain plug (1) if removed during the draining process.

    3. Tighten
    Tighten the water pump drain plug to 22 N·m (16 lb in).

  3. Lower the vehicle.
  4. Fill the cooling system.
  5. 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.

    6. Important: 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.


    Object Number: 873722 Size: SH
  6. Install surge tank cap.
  7. Start the engine.
  8. Run the engine at 2,000-2,500 RPM for 3 minutes.
  9. Allow the engine to idle for 30 seconds.
  10. Shut the engine off.
  11. Top off the coolant as necessary.
  12. Inspect the cooling system for leaks.
  13. Rinse away any excess coolant from the engine and the engine compartment.