Cooling System Draining and Filling (Static Fill)

Draining and Filling Cooling System (L61)

Tools Required

J 26568 Coolant and Battery Fluid Tester

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.




1. Unscrew the surge tank cap to remove vacuum when draining coolant.
2. Place a container under the radiator drain.




3. Unscrew the radiator drain plug until coolant flows out of the radiator drain.
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.





Important: Draining at water pump will drain the heater core and some of the engine block.

5. Place a container under the water pump housing and open the water pump drain plug.
6. Follow the appropriate procedure based on the condition of coolant.
^ Normal in appearance-Follow filling procedure.
^ Discolored-Follow flush procedure. Refer to Flushing.

Fill Procedure

Notice: 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 plug.
2. Close the water pump drain plug. Refer to Water Pump Installation for the 2.2L.(L61) engine.
3. Lower the vehicle.
4. Vehicle should be level.




5. Add a mixture of 50/50 DEX-COOL(R) antifreeze and clean drinkable water until the level stabilizes approximately 25.4 mm (1.0 in) above the weld seam on the surge tank. Refer to Capacities - Approximate Fluid.




6. Install the surge tank cap.

Important: DO NOT exceed 2,200 RPM.

7. Start the engine and run at 2,000 RPM until the engine cooling fans turn ON.
8. Turn the engine OFF and allow the engine to cool down.
9. Remove the surge tank cap.
10. Refill to approximately 25.4 mm (1.0 in) above the weld seam on the surge tank.
11. Inspect the concentration of engine coolant using J 26568.
12. Install the surge tank cap.
13. Rinse away any excess coolant from the engine and the engine compartment.