Cooling System Draining and Filling

Cooling System Draining and Filling

Tools Required
* J 26568 Coolant and Battery Fluid Tester
* J 42401 Radiator Pressure Adapter
* GE-47716 Vac N Fill Coolant Refill Tool

Draining Procedure




1. Unscrew the surge tank cap to remove vacuum when draining the coolant.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
3. Place a container under the radiator drain.
4. Unscrew the radiator drain plug until coolant flows out the radiator drain.
5. If a complete block drain is required, remove the drain plugs. Refer to Draining Fluids and Oil Filter Removal (1. Draining Fluids and Oil Filter Removal) for the 2.4L engine, or Engine Block Disassemble () for the 3.6L engine.
6. 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 (Flushing).

Vac N Fill Procedure

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.


If a complete engine block drain was required, install the engine block drain plugs. Refer to the appropriate procedure:

* Engine Block Assemble () for the 2.4L engine
* Engine Block Disassemble () for the 3.6L engine




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




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




6. Attach the fill hose to the barb fitting on the vacuum gauge assembly.
Ensure the valve is closed.





Important: Use a 50/50 mixture of DEX-COOL(R) 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 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 gauge assembly and the vacuum tank.




13. Open the valve on the venturi assembly. The vacuum gauge 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 coolant fill port.




16. 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.
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 (Loss of Coolant).
19. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.




20. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 11-17.
21. Remove the J-42401-3 from the surge tank fill neck.
22. Remove J-42401-2 from the surge tank fill neck.
23. Detach the Vac N Fill cap from the vehicles coolant fill port.
24. Add coolant to the system as necessary.
25. 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.


26. Detach the vacuum hose from the vacuum gauge assembly.




27. Attach the extraction hose to the vacuum hose.




28. Open the valve on the venturi assembly to start a vacuum draw.




29. Use the extraction hose to draw out coolant to the proper level.
30. Install the surge tank cap.
31. 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.