Draining and Filling Cooling Systems

Draining and Filling Cooling System (L61)

^ Tools Required
- J 26568 Coolant and Battery Tester

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.

1. Remove the coolant pressure cap.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Place a drain pan under the drain cock.
4. Open the radiator drain cock.
5. Drain the cooling system.
6. If a complete engine block drain is required, remove the engine block drain plug.
7. Inspect the engine coolant for the following:
^ Discolored - follow the flush procedure.
^ Normal in appearance - follow the filling procedure.
^ If a complete block drain is required, remove the water pump drain plug.

Filling Procedure

1. Notice: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage. Refer to Fastener Notice in Service Precautions.

Close the radiator drain cock.
Tighten radiator drain cock to 2 Nm (18 inch lbs.).
2. Install the water pump drain plug if necessary.
Tighten the water pump drain plug to 22 Nm (16 ft. lbs.).
3. Lower the vehicle.
4. Fill the cooling system.
5. Slowly add a mixture of 50/50 DEX-COOL and clean, drinkable water.

Important: It is necessary to maintain the coolant level at the top of the surge tank label to insure all the air has been purged from the cooling system.

6. Install surge tank cap.
7. Start the engine.
8. Run the engine at 2,000 - 2,500 RPM until engine reaches normal operating temperature.
9. Allow the engine to idle for 3 minutes.
10. Shut the engine off.
11. Allow the engine to cool.
12. Top off the coolant as necessary.
13. Inspect the cooling system for leaks.
14. Rinse away any excess coolant from the engine and the engine compartment.
15. Inspect the concentration of the engine coolant using J 26568.