Engine Coolant - Revised Service Fill Procedure
File In Section: 6 - EngineBulletin No.: 63-62-03
Date: February, 1996
SERVICE MANUAL UPDATE
Subject:
Section 6B - Revised Engine Coolant Service Fill Procedure
Models:
1996 Chevrolet Cavalier
1996 Pontiac Sunfire
with 2.2L Engine (VIN 4 - RPO LN2)
This bulletin revises the engine coolant service fill procedure found on page 6B-8 of the 1996 "J" car Service Manual.
Please replace the current procedure with the following:
Important:
The use of mechanical fill equipment is not recommended.
Coolant Service Fill Procedure (WITHOUT ENGINE VENT LINE)
1. Close the radiator drain valve and remove drain tube.
2. Install all engine block drain plugs if previously removed.
Use pipe sealer when installing drain plugs.
3. When adding coolant, it is important that GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant meeting GM specification 6277M be used. If silicated coolant is added to the system, premature engine, heater core, or radiator corrosion may result. In addition, the engine coolant will require change sooner - at 50,000 km (30,000 miles) or 24 months.
4. Open BOTH bleeder valves - one on the heater return pipe and one on the water outlet (see Figure 1).
5. Fill the cooling system through the surge tank until coolant is expelled out BOTH bleeder valves.
6. Close bleeder valves.
7. Top off coolant level in surge tank to a level even with the flat horizontal wall below the vent lines (approximately 1" below fill neck), (see Figure 2).
Important:
Leave surge tank cap off.
8. Start engine.
9. Open water outlet bleeder valve and leave valve open until a solid stream of coolant is expelled, then close valve. Repeat this every 3 minutes until the thermostat opens.
Important:
Thermostat is considered open when upper radiator hose is hot at radiator connection.
Important:
Turn HVAC controls to "Heater", Full Hot and check for warm air during the first 5 minutes after engine start. If no hot air is present, start procedure again at Step 4.
10. Top off coolant, if necessary, to the same level as in Step 7.
11. Install surge tank cap.
Coolant Service Fill Procedure (WITH ENGINE VENT LINE)
1. Close the radiator drain valve and remove drain tube.
2. Install all engine block drain plugs if previously removed.
Use pipe sealer when installing drain plugs.
3. When adding coolant, it is important that GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant meeting GM specification 6277M be used. If silicated coolant is added to the system, premature engine, heater core, or radiator corrosion may result. In addition, the engine coolant will require change sooner, at 50,000 km (30,000 miles) or 24 months.
4. Open the bleeder valve on the heater return pipe (see Figure 3).
5. Fill the cooling system through the surge tank until coolant is expelled out the heater return pipe bleeder valve.
6. Close bleeder valve.
7. Top off coolant level in surge tank to a level even with the flat horizontal wall below the vent lines (approximately 1" below fill neck), (see Figure 2).
Important:
Leave surge tank cap off.
8. Start engine and warm engine up until the thermostat opens.
Important:
Thermostat is considered open when upper radiator hose is hot at radiator connection.
Important:
Turn HVAC controls to "Heater", Full Hot and check for warm air during the first 5 minutes after engine start. If no hot air is present, start procedure again at Step 4.
9. Top oft coolant, if necessary, to the same level as in Step 7.
10. Install surge tank cap.