Vac-N-Fill Procedure
CAUTION:
The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.
- After draining the system, close the drain cock (1) on the radiator.
- Remove the drain hose from the radiator drain port (2).
- Lower the vehicle.
- The vehicle should be level before filling the cooling system.
- Install GE-42401-2
adapter into the surge tank fill neck.
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.
- Install GE-42401-3 adapter to the surge tank fill neck.
- Attach the Vac N Fill cap to the GE-42401-3 adapter.
- Attach the vacuum gauge assembly to the Vac N Fill cap.
- Attach the fill hose to the barb fitting on the vacuum gauge assembly.
Courtesy of GENERAL MOTORS COMPANY
Ensure that the valve is closed.
- Pour the coolant mixture into the graduated reservoir.
NOTE:
Use a 50/50 mixture of DEX-COOL anti-freeze and clean, drinkable water.
Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.
- Place the fill hose in the graduated reservoir.
- Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.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.
- Attach the venturi assembly to the vacuum tank.
- Attach a shop air hose to the venturi assembly.
Ensure the valve on the venturi assembly is closed.
- Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
- Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
- 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.
- To aid in the fill process, position the graduated reservoir above the coolant fill port.
- 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.
- Close the valve on the venturi assembly.
- 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 .
- Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
- Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 13- 19.
- Detach the Vac N Fill cap from the surge tank.
- Slowly remove the vent screw (1) on the radiator until coolant begins to flow from the vent port.
NOTE: The vent screw has a feature (2) to allow air to escape when the vent screw is in the open position.
- Tighten the vent screw (1) to 1.9 N.m (17 lb in).CAUTION: Refer to Fastener Caution .
- Detach the vacuum hose from the vacuum gauge assembly.NOTE: After filling the cooling system, the extraction hose can be used to remove excess coolant to achieve the proper coolant level.
- Attach the extraction hose to the vacuum hose.
- Open the valve on the venturi assembly to start a vacuum draw.
- Add or remove coolant at the surge tank until the coolant level is at the cold fill indicator marking on the surge tank (1).
- Start the engine.NOTE: The A/C system must be turned OFF to ensure the cooling fans do not cycle during engine warm up.
- Turn the A/C system OFF.
- After starting the engine, wait two minutes for the coolant level to stabilize within the surge tank and coolant to flow through the surge tank vent port (2). If necessary, add coolant to the surge tank until the coolant level is at the cold fill indicator marking on the surge tank (1).
- Install the coolant surge tank cap.
- Run the engine at 2500 RPM until the thermostat opens and the coolant fans cycle ON and OFF at least two separate times.
- Turn the engine OFF.
- Remove the surge tank cap.NOTE: The engine must be allowed to completely cool down to under 49°C (120°F) to ensure a proper coolant fill.
- Inspect the concentration of the engine coolant, using GE-26568 Coolant and Battery Fluid Tester. Adjust concentration as necessary prior to adding additional coolant.
- Slowly remove the vent screw (1) on the radiator until coolant begins to flow from the vent port.
- Tighten the vent screw (1) to 1.9 N.m (17 lb in).
- Add coolant to the surge tank until the coolant level is 9.0 mm (0.35 in) above the coolant fill indicator marking (1).
- Install the surge tank cap.
- Clean any excess coolant from the engine and the engine compartment.
- 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.