Cooling System Draining and Filling (Vac-N-Fill)

Draining and Filling Cooling System (Vac N Fill)

Tools Required
^ J 26568 Coolant and Battery Tester
^ J 38185 Hose Clamp Pliers
^ J 42401 Radiator Cap and Surge Tank Test Adapter
^ GE-47716 Vac N Fill Coolant Refill Tool

Draining Procedure
1. Park the vehicle on a level surface.

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.

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

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.

Filling Procedure





1. Install the J 42401.
2. Attach the Vac N Fill cap to the vehicle's coolant fill port.

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.





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.





5. Pour the coolant mixture into the graduated reservoir.

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.

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

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.





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).
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 test.
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 vehicle's coolant fill port.
22. Add coolant to the system as necessary.
23. Inspect the concentration of the coolant mixture using J 26568.
24. Detach the vacuum hose from the vacuum gage assembly.

Important: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.





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.