Drive Motor Battery Cooling System Draining and Filling

Drive Motor Battery Cooling System Draining and Filling

Special Tools

* GE-26568 - Coolant and Battery Tester

* GE-47716 - Vac-N-Fill Coolant Refill Tool

* GE-46143 - Cooling System Adapter

For equivalent regional tools, Refer to Special Tools Tools and Equipment

Draining Procedure

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: Draining of the cooling system or replacement of any drive motor battery cooling system parts requires the actuation of the Hybrid/EV Battery Pack Coolant Pump Bleed Procedure in the GDS tool.

1. Remove the drive motor generator battery bracket if equipped. Refer to Drive Motor Generator Battery Bracket Replacement (Surge Tank) Drive Motor Generator Battery Bracket Replacement (Surge Tank).

2. Remove the battery radiator inlet hose from the quick connect at the right frame rail. Refer to Drive Motor Battery Radiator Inlet Hose Replacement Drive Motor Battery Radiator Inlet Hose Replacement

3. 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 Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement

4. Inspect the coolant.

5. 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 Flushing.

Vac-N-Fill Procedure

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 vehicles 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 fill hose to the barb fitting on the vacuum gauge assembly.
Ensure that the valve is closed.

Note: Use a Pre-mixed Dexcool(R) (50/50 mixture of Dexcool(R) and deionized 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 venturi assembly to the vacuum tank.

9. Attach a shop air hose to the venturi assembly.
Ensure the valve on the venturi assembly is closed.

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

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

12. 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.

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 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 Hybrid Cooling System Loss of Coolant (Power Electronics) Hybrid Cooling System Loss of Coolant (Power Electronics)Hybrid Cooling System Loss of Coolant (Battery) Hybrid Cooling System Loss of Coolant (Battery).

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 (1) reaches zero, close the valve on the vacuum gauge assembly and repeat steps 12-18.

19. Place vehicle in Service Mode. With the GDS scan tool, initiate the hybrid/EV battery pack coolant pump bleed procedure while maintaining 381 mm (15 in Hg) vacuum throughout the process. This procedure will take about one hour to complete.

20. Detach the Vac-N-Fill cap from the GE-46143 - Cooling System Adapter.

21. Remove GE-46143 - Cooling System Adapter from the surge tank fill neck.

Note: Two different designs of surge tanks (1, 5) are in use. The second design incorporates an anti-tamper bracket (4) and coolant level sensor (8), and the first design does not. Disregard factory coolant level indicator markings (2, 7) on first and second design surge tanks.

22. Upon completion of the hybrid/EV battery pack coolant pump bleed procedure, adjust the surge tank coolant level to a position just above the seam (3, 6) on the side of the tank (1, 5).

23. Inspect the concentration of the coolant mixture using GE-26568 - Coolant and Battery Tester.

REMOVING EXCESS COOLANT FROM SYSTEM

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

1. Detach the vacuum hose from the vacuum gauge assembly.

2. Attach the extraction hose to the vacuum hose.

3. Open the valve on the venturi assembly to start a vacuum draw.

4. Assemble the extraction hose (1) and insert into the surge tank (2).