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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 2002 (Hybrid Cooling System - 3.6L (Hp5)) >> Repair Instructions >> Generator Control Module Cooling System Draining and Filling >> Filling Procedure

Filling Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.
    NOTE: Use pre-mixed DEX-COOL only. Pre-mix DEX-COOL contains the proper 50/50 mixture of DEXCOOL and de-ionized water necessary to prevent corrosion damage to the generator control module internal heat sink. Never use tap water in the hybrid cooling system.
  1. Install the surge tank outlet hose to the air separator.
  2. Reposition the surge tank outlet hose clamp on the air separator.
  3. Install the air separator bolt to the vehicle and tighten to 9 N.m (80 lb in).
    4. NOTE: Use pre-mixed DEX-COOL only. Pre-mix DEX-COOL contains the proper 50/50 mixture of DEXCOOL and de-ionized water necessary to prevent corrosion damage to the generator control module internal heat sink. Never use tap water in the hybrid cooling system.
  4. Remove the right headlamp. Refer to Headlamp Replacement
    5. Fig 1: Hybrid Radiator Inlet Hose
    GM2142975Courtesy of GENERAL MOTORS CORP.
  5. Reposition the hybrid radiator inlet hose clamp (1).
  6. Remove the hybrid radiator inlet hose from the hybrid radiator (2).
  7. Using a clean flexible funnel or similar tool, slowly fill the hybrid radiator with the pre-mixed DEX-COOL and de-ionized water. Refer to Approximate Fluid Capacities (Two Mode Hybrid) or Approximate Fluid Capacities (Green Line Hybrid)
    8. Fig 2: Surge Tank
    GM2143007Courtesy of GENERAL MOTORS CORP.
  8. With the hybrid radiator inlet hose positioned upward, slowly add the pre-mixed DEX-COOL and de-ionized water to the surge tank (1) until coolant is visible in the hybrid radiator inlet hose.
  9. Install the hybrid radiator inlet hose to the hybrid radiator.
  10. Reposition the hybrid radiator inlet hose clamp.
  11. Turn the ignition ON.
  12. As the cooling pumps run, air will purge into the surge tank and the coolant level will drop. Top off the coolant as necessary until the coolant is maintained at the Cold Full line.
  13. Install the coolant pressure cap.
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