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Engine Cooling System: Maintenance Chevrolet Malibu VIII рестайлинг

Cooling System (Mechanical) 2 illustrations ~987 words

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United StatesCanada
Extended Life Coolant Leak Detection DyeDye8902221989022220
DEX-COOLCoolant1234629010953464

Adhesives, Fluids, Lubricants, and Sealers

Scheme 43

Scheme 43: Cooling Fans
Scheme 43: Cooling Fans

Draining Procedure

WARNINGTo avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
  1. Remove the coolant pressure cap.
  2. Remove the right front wheelhouse liner to gain access to the drain plug.
  3. Place a drain pan under the drain cock.
  4. Open the radiator drain cock.
  5. Drain the cooling system.
  6. If a complete engine block drain is required, remove the coolant drain plugs from the engine block.
  7. Inspect the coolant.
  8. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «Flushing»(ref-609148-S24244654622014041500000) .
WARNINGWith 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. Remove the coolant pressure cap.
  2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-609111-S25517100942014041500000) .
  3. Remove the right front wheelhouse front liner. Refer to «Front Wheelhouse Front Liner Replacement (Left Side)»(ref-609146-S14630192292014041500000) , «Front Wheelhouse Front Liner Replacement (Right Side)»(ref-609146-S05893536892014041500000) .
  4. Place a drain pan under the drain cock.
  5. Remove the radiator drain cock (1).
  6. Drain the cooling system.
  7. Install the drain plug (1).
  8. Lower the vehicle.
  9. Inspect the coolant.
  10. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «Flushing»(ref-609148-S24244654622014041500000) .

Vac-N-Fill Procedure

  1. Install the J 42401 Radiator Cap and Surge Tank Test Adapter onto the coolant surge tank.
  2. Attach the Vac N Fill cap to the J 42401 Radiator Cap and Surge Tank Test Adapter (1).
  3. Attach the vacuum gauge assembly (1) to the Vac N Fill cap (2).
  4. Attach the fill hose (1) to the barb fitting on the vacuum gauge assembly (2). Ensure that the valve is closed.
  5. Pour the coolant mixture into the graduated reservoir (1).
  6. Place the fill hose in the graduated reservoir (1).
  7. Install the vacuum tank (2) on the graduated reservoir with the fill hose routed through the cut-out area (3) in the vacuum tank.
  8. Attach the venturi assembly (1) to the vacuum tank (2).
  9. Attach a shop air hose to the venturi assembly (1). Ensure the valve (2) on the venturi assembly is closed.
  10. Attach the vacuum hose (1) to the vacuum gauge assembly (2) and the vacuum tank (3).
  11. Open the valve (1) on the venturi assembly (2). The vacuum gauge will begin to rise and a hissing noise will be present.
  12. Continue to draw vacuum until the needle stops rising (1). This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
  13. To aid in the fill process, position the graduated reservoir above the coolant fill port.
  14. Slowly open the valve (1) on the vacuum gauge assembly (2). When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
  15. Close the valve on the venturi assembly.
  16. 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»(ref-609148-S07951242992014041500000) .
  17. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
  18. Once the vacuum gauge reaches zero (1), close the valve on the vacuum gauge assembly and repeat steps 11-17.
  19. Detach the Vac N Fill cap from the J 42401 Radiator Cap and Surge Tank Test Adapter.
  20. Remove the J 42401 Radiator Cap and Surge Tank Test Adapter from the coolant surge tank.
  21. Add coolant to the system as necessary.
  22. Inspect the concentration of the coolant mixture using J 26568 Coolant and Battery Fluid Tester.
  23. Detach the vacuum hose from the vacuum gauge assembly.
  24. Attach the extraction hose (1) to the vacuum hose (2).
  25. Open the valve (1) on the venturi assembly (2) to start a vacuum draw.
  26. Use the extraction hose (1) to draw out coolant to the proper level.
  27. 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.
  28. Install the surge tank cap.
  29. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-609111-S25517100942014041500000) .
  30. Install the right front wheelhouse front liner. Refer to «Front Wheelhouse Front Liner Replacement (Left Side)»(ref-609146-S14630192292014041500000) , «Front Wheelhouse Front Liner Replacement (Right Side)»(ref-609146-S05893536892014041500000) .
  31. Lower the vehicle.

Flushing

Note. Do not use a chemical flush.

Store used coolant in a properly labeled container. 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.

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. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  2. Remove the coolant recovery reservoir. Refer to «Radiator Surge Tank Replacement (LKW)»(ref-609148-S31213676532014041500000) , «Radiator Surge Tank Replacement (LUK)»(ref-609148-S35581657362014041500000) , «Radiator Surge Tank Replacement (LTG)»(ref-609148-S39956805052014041500000) .
  3. Clean and flush the coolant recovery reservoir with clean, drinkable water.
  4. Install the coolant recovery reservoir. Refer to «Radiator Surge Tank Replacement (LKW)»(ref-609148-S31213676532014041500000) , «Radiator Surge Tank Replacement (LUK)»(ref-609148-S35581657362014041500000) , «Radiator Surge Tank Replacement (LTG)»(ref-609148-S39956805052014041500000) .
  5. Follow the drain and fill procedure using only clean, drinkable water. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  6. Run the engine for 20 minutes.
  7. Stop the engine.
  8. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .
  9. Repeat the procedure if necessary, until the fluid is nearly colorless.
  10. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) .

Scheme 44

Scheme 44: Radiator Surge Tank Replacement (LKW)
Scheme 44: Radiator Surge Tank Replacement (LKW)
CalloutComponent Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static) , Cooling System Draining and Filling (GE 47716) Remove the radiator surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose Replacement (LKW) . Remove the heater outlet hose. Refer to Heater Outlet Hose Replacement (Heater Core Outlet Tube to Heater Outlet Pipe LKW) , Heater Outlet Hose Replacement (Auxiliary Water Pump to Heater Outlet Pipe LKW) and Heater Outlet Hose Replacement (Radiator Surge Tank Auxiliary to Warer Pump to Water Outlet LKW) .
1Radiator Surge Tank Retainer
2Radiator Surge Tank Procedure Slide the surge tank forward towards the front of the car to remove from brackets.

Radiator Surge Tank Replacement (LKW)

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