Drive Motor Battery Cooling System Draining and Filling

Drive Motor Battery Cooling System Draining and Filling

Special Tools
* GE-47716 - Vac-N-Fill Coolant Refill Tool
* J-38185 - Hose clamp Pliers

Draining Procedure




1. Connect GE-47716 - Vac-N-Fill Coolant Refill Tool (1) to drain valve opening and secure with clamp.
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2. Remove radiator cap (1).
3. To evacuate coolant follow the steps on the GE-47716 - Vac-N-Fill Coolant Refill Tool.




4. Turn the drain valve (1) counterclockwise to open.




5. To assist the coolant evacuation, place palm over the coolant filler opening (1) for 30 seconds, then remove (2); repeat 3 times.




6. Using J-38185 - Hose clamp Pliers slide the spring clamp (1) off of the upper cassette coolant manifold 90° fitting.




7. To assist in the coolant evacuation, place a finger (1) over the upper cassette coolant manifold 90° fitting opening for 30 seconds, then remove (2); repeat 3 times.




8. To assist in the coolant evacuation, place a thumb (1) over the straight hose opening for 30 seconds, then remove (2); repeat 3 times.




9. Using J-38185 - Hose clamp Pliers install the spring clamp (1) and hose to the upper cassette coolant manifold 90° fitting.




10. Turn the drain valve (1) clockwise to close.




11. Install radiator cap (1), and remove GE-47716 - Vac-N-Fill Coolant Refill Tool.

Vac-N-Fill Procedure

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. Install J 42401-2 into the radiator fill neck.
2. Install J 42401-3 to the radiator fill neck.
3. Attach the Vac N Fill cap to the J 42401-3.




4. Attach the vacuum gage assembly to the Vac N Fill cap.




5. 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 de-ionized water.

Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.

6. Pour the coolant mixture into the graduated reservoir.
7. 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.

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




9. Attach the venturi assembly to the vacuum tank.




10. Attach a shop air hose to the venturi assembly.
Ensure the valve on the venturi assembly is closed.




11. Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.




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 radiator.




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. Open the valve on the vacuum gage assembly. The vacuum gage will drop as coolant is drawn into the system.




18. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 12-17.




19. Connect the coolant pump jumper (1) to the coolant pump power supply connector.
20. Set the power supply to 12 V and let run for five minutes.




21. Detach the Vac N Fill cap from the J 42401-3.
22. Remove J 42401-2 from the radiator fill neck.
23. Add coolant to the system as necessary.
24. Inspect the concentration of the coolant mixture using J 26568 - Coolant and Battery Fluid Tester.

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

25. Detach the vacuum hose from the vacuum gage assembly.
26. Attach the extraction hose to the vacuum hose.




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




28. Use the extraction hose to draw out coolant to the proper level.
29. 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.