Cooling System Draining and Filling Static Fill

Special Tools

J 26568 Coolant and Battery Tester

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. Place a drain pan under the radiator hose.
2. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement.
3. Move down the end of the radiator hose to drain the radiator.
4. Drain the cooling system.
5. Remove the coolant pressure cap.
6. If a complete engine block drain is required, remove the engine drain plugs.
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.

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

1. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement.

Caution: Refer to Fastener Caution in the Preface section.

2. If the engine block drain plug was removed, perform the following:

2.1.	Apply pipe sealer to the drain plugs.

2.2.	Install the drain plugs.

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

3. Lower the vehicle.

Note: 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. Refer to Approximate Fluid Capacities.
5. Install the coolant pressure cap.
6. Start the engine.
7. Run the engine at 2,000-2,500 RPM until the engine reaches normal operating temperature.
8. Allow the engine to idle for 3 minutes.
9. Shut the engine OFF.
10. Allow the engine to cool.
11. Top off the coolant as necessary.
12. Inspect the concentration of the engine coolant, using the J 26568 .
13. Rinse away any excess coolant from the engine and the engine compartment.

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.

1. Remove the radiator cap.



2. Attach the venturi assembly to the vacuum tank.



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

Ensure the valve on the venturi assembly is closed.

4. Attach the vacuum hose to the vacuum tank.



5. Attach the extraction hose to the vacuum hose.
6. Insert the extraction hose into the radiator cap opening and into the radiator until the extraction hose contacts the bottom of the radiator end tank.



7. Open the valve on the venturi assembly to start a vacuum draw.
8. Use the extraction hose to draw out coolant until the radiator is empty.
9. 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.
10. If a complete engine block drain is required, remove the engine block drain plug.
11. Inspect the coolant.
12. 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.

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. Attach the Vac-N-Fill cap to the vehicles coolant fill port.
2. Install the extension hose.



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 venturi assembly to the vacuum tank.



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

Ensure the valve on the venturi 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 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.



19. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 11-17.

Remove the extension hose.

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 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.