Cooling System: Service and Repair

Draining and Filling Cooling System

Tools Required
^ J 38785 Hose Clamp Pliers

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

Important: If the procedure below is not followed a low or high coolant level condition and/or vehicle damage could result

1. Park the vehicle on a level surface.
2. Allow the engine to cool.
3. Remove the radiator cap.
4. Raise and support 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 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.
^ Normal in appearance - follow the filling procedure.
^ If a complete block drain is required, remove the block drain located on the LH side of the block, or removing the heater inlet hose at the right rear of the engine block. Fill the system using the Special Coolant Fill Procedure.

Tools Required
^ J 38185 Hose Clamp Plier
Radiator and Shroud Components (p72) Coolant and Battery Tester

Fill Procedure

Important: Due to the system configuration, standard filling procedure may not ensure a complete system fill. The standard coolant fill procedure applies to conditions coolant was drained only through the radiator hose. The special coolant fill procedure must be used if any of the following events have occurred.

^ Engine block drain removed or replaced.
^ Water pump seal is broken or pump was replaced.
^ Thermostat removal.
^ Auxiliary coolant pump removal.
^ Complete engine removed or replace.

Standard Coolant Filling Procedure
1. Install the lower radiator hose.
2. Using the J 38185 slide the clamp into the original position.
3. Lower the vehicle.
4. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized wafer to the cooling system through the top of the radiator until full.
5. Install the radiator cap.
6. Remove coolant recovery reservoir cap.
7. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized wafer to the cooling system through the coolant recovery reservoir.
8. Fill the coolant recovery reservoir until the coolant reaches the "Full Cold" mark on the coolant recovery reservoir.
9. Install coolant recovery reservoir cap.
10. Start the engine.
11. Run the engine at 2,000-2,500 RPM until the engine reaches normal operating temperature.
12. Allow the engine to idle for 3 minutes.
13. Shut the engine off.
14. Allow the engine to cool.
15. Top off the coolant recovery reservoir as necessary.
16. Inspect the cooling system for leaks.
17. Rinse away any excess coolant from the engine and the engine compartment.
18. Inspect the concentration of the engine coolant using.

Special Coolant Fill Procedure
1. Install the lower radiator hose.
2. Using the J 38185 slide the clamp into the original position.
3. Lower the vehicle.
4. Using the J 38185 remove the upper radiator hose from the radiator connection.
5. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized wafer to the cooling system through the top of the radiator opening.
6. Fill the upper radiator hose and engine with the 50/50 coolant mixture.
7. Connect the upper radiator hose to the engine.
8. Using the J 38185 slide the radiator hose clamp into the original position.
9. Fill the coolant recovery reservoir to the "Full Cold".
10. Install the coolant recovery reservoir cap.
11. Idle the engine for 2 minutes and occasionally raise the throttle to 3,000-3,500 RPM.
12. Shut off the engine and allow it to cool.
13. Repeat the steps 1 - 9.
14. Idle the engine for 2 minutes and occasionally raise the throttle to 3,000-3,500 RPM.
15. Inspect the coolant recovery reservoir for consistent flow.
16. If there is no flow through the coolant recovery reservoir repeat steps 1 - 9.
17. Allow engine to cool.
18. Remove the coolant recovery reservoir cap and fill to the "Full Cold".

Flushing

Important: Do not use a chemical flush.

Store used coolant in the proper manner, such as in a used engine coolant holding tank. Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical. Do not dispose of coolant into the sewer system or ground water. This is illegal and ecologically unsound.
Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a back flusher, follow the manufacturer's instruction. Always remove the thermostat before flushing the cooling system. When the cooling system becomes contaminated, the cooling system should be flushed thoroughly to remove the contaminants before the engine is seriously damaged.
1. Drain the cooling system.
2. Remove the coolant recovery reservoir.
3. Clean and flush the coolant recovery reservoir with clean, drinkable water.
4. Install the coolant recovery reservoir.
5. Remove the thermostat.
6. Follow the drain and fill procedure using only clean, drinkable water.
7. Run the engine for 20 minutes.
8. Stop the engine.
9. Drain the cooling system.
10. Repeat the procedure if necessary, until the fluid is nearly colorless.
11. Install the thermostat.
12. Fill the cooling system.

Radiator Cleaning

Caution: NEVER spray water on a hot radiator. The resulting steam could cause personal injury.

Notice: The radiator fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer

Important: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator.

^ Some conditions may require the use of warm water and a mild detergent.
^ Clean the A/C condenser fins.
^ Clean between the A/C condenser and radiator.
^ Clean the radiator cooling fins.
^ Straighten any damaged cooling fins.