Volt

Drive Motor Battery Cooling System Draining and Filling

Special Tools

For equivalent regional tools, Refer toSpecial Tools

Warning: To 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 battery radiator inlet hose from the quick connect at the right frame rail. Refer to Drive Motor Battery Radiator Inlet Hose Replacement
2. To drain the battery coolant, remove the battery hose quick connect at the battery. Refer to Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement
3. Inspect the coolant.
4. Follow the appropriate procedure based on the condition of the coolant.

•	Normal in appearance--Follow the filling procedure.

•	Discoloured--Follow the flush procedure. Refer to Flushing .

Warning: To 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.

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.

1. Install GE-46143 Cooling System Adapter
2. Attach the Van-N-Fill cap to GE-46143 Cooling System Adapter .



3. Attach the vacuum gauge assembly to the Vac-N-Fill cap.



4. Attach the filling hose to the barb fitting on the vacuum gauge assembly.

Ensure that the valve is closed.





Note: Use a Pre-mixed Dexcool® (50/50 mixture of Dexcool® and deionised water). Always use more coolant than necessary. This will eliminate air from being drawn into the cooling system.

5. Pour the coolant mixture into the graduated reservoir.
6. Place the fill hose in the graduated reservoir.

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.

7. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.



8. Attach the venture assembly to the vacuum tank.



9. Attach a shop air hose to the venture assembly.

Ensure the valve on the venture assembly is closed.




10. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.



11. Open the valve on the venture assembly. The vacuum gauge will begin to rise and a hissing noise will be present.



12. Continue to draw a 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.

13. To aid in the fill process, position the graduated reservoir above the coolant fill port.



14. 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.
15. Close the valve on the venture assembly.
16. If there is a suspected leak in the cooling system, allow the system to stabilise under vacuum and monitor for vacuum loss.

If vacuum loss is observed, refer to Loss of Coolant .

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, close the valve on the vacuum gauge assembly and repeat steps 12-18.
19. Detach the Vac-N-Fill cap from the GE-46143 Cooling System Adapter .
20. Remove GE-46143 Cooling System Adapter from the surge tank filler neck.
21. Add coolant to the system as necessary.
22. Inspect the concentration of the coolant mixture using GE-26568 Coolant and Battery Tester.

Note: After filling the cooling system, the extraction hose can be used to remove excess coolant and achieve the proper coolant level.

23. Detach the vacuum hose form the vacuum gauge assembly.



24. Attach the extraction hose to the vacuum hose.



25. Open the valve on the venture assembly to start a vacuum draw.



26. Use the extraction hose 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.