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Vac-N-Fill Procedure

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Radiator Drain Cock
    GM877653Courtesy of GENERAL MOTORS CORP.
    CAUTION: The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.
  1. Close the radiator drain cock by hand.
    2. Fig 2: Identifying Vac-N-Fill Cap
    GM1617435Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  2. Install J-42401-2 into the surge tank fill neck.
  3. Install J-42401-3 to the surge tank fill neck.
  4. Attach the Vac N Fill cap to the J-42401-3.
    5. Fig 3: Attaching The Vacuum Gage Assembly To The Vac-N-Fill Cap
    GM1617436Courtesy of GENERAL MOTORS CORP.
  5. Attach the vacuum gauge assembly to the Vac N Fill cap.
    6. Fig 4: Attaching Fill Hose To Barb Fitting On Vacuum Gage Assembly
    GM1617437Courtesy of GENERAL MOTORS CORP.
  6. Attach the fill hose to the barb fitting on the vacuum gauge assembly.

    Ensure that the valve is closed.

    7. Fig 5: View Of Graduated Reservoir & Hose
    GM1617438Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
  7. Pour the coolant mixture into the graduated reservoir.
  8. Place the fill hose in the graduated reservoir.
    9. 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.
  9. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
    10. Fig 6: Connecting Venturi Assembly To Vacuum Tank
    GM1617439Courtesy of GENERAL MOTORS CORP.
  10. Attach the venturi assembly to the vacuum tank.
    11. Fig 7: Attaching Shop Air Hose To Venturi Assembly
    GM1617440Courtesy of GENERAL MOTORS CORP.
  11. Attach a shop air hose to the venturi assembly.

    Ensure the valve on the venturi assembly is closed.

    12. Fig 8: Attaching Vacuum Hose To Vacuum Gauge Assembly & Vacuum Tank
    GM1617441Courtesy of GENERAL MOTORS CORP.
  12. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
    13. Fig 9: Identifying Valve On Venturi Assembly
    GM1617442Courtesy of GENERAL MOTORS CORP.
  13. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
    14. Fig 10: View Of Vacuum Gauge
    GM1617443Courtesy of GENERAL MOTORS CORP.
  14. 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.

  15. To aid in the fill process, position the graduated reservoir above the surge tank.
    16. Fig 11: Identifying Valve On Vacuum Gage Assembly
    GM1617446Courtesy of GENERAL MOTORS CORP.
  16. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
  17. Close the valve on the venturi assembly.
  18. 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 .

  19. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
    20. Fig 12: View Of Vacuum Gauge & Radiator
    GM1617448Courtesy of GENERAL MOTORS CORP.
  20. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 10-16.
  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. NOTE: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.
  24. Detach the vacuum hose from the vacuum gauge assembly.
    25. Fig 13: Attaching Extraction Hose To Vacuum Hose
    GM1617450Courtesy of GENERAL MOTORS CORP.
  25. Attach the extraction hose to the vacuum hose.
    26. Fig 14: Identifying Valve On Venturi Assembly
    GM1617453Courtesy of GENERAL MOTORS CORP.
  26. Open the valve on the venturi assembly to start a vacuum draw.
    27. Fig 15: Using Extraction Hose To Draw Out Coolant
    GM1617456Courtesy of GENERAL MOTORS CORP.
  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.
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