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    1993 GMC Truck G3500HD 1 ton Van 6.2L Diesel 8cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Mercury Villager 2000-2002

    Drain, Flush & Refill

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    Ensure that the engine is completely cool prior to starting this service.


    CAUTION
    Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    1. Remove the radiator and recovery tank caps.
    2.  
    3. Raise and safely support the front of the vehicle securely on jackstands.
    4.  
    5. Remove the passenger-s side splash shield from under the front of the vehicle.
    6.  
    7. Place a drain pan of sufficient capacity under the radiator and open the petcock (drain) on the radiator.
      NOTE
      Plastic petcocks easily bind. Before opening a plastic radiator petcock, spray it with some penetrating lubricant.

    8.  
    9. Place drain pans under the engine block. Remove the two engine block drain plugs, which are located on either side of the lower block, toward the front (passenger-s side) of the engine.
    10.  
    11. Drain the cooling system completely.
    12.  
    13. Apply silicone sealant to the engine block drain plugs. Install the plugs and tighten them to 25-33 ft. lbs. (34-44 Nm).
    14.  
    15. Close the petcock.
    16.  
    17. Remove the drain pans.
    18.  
    19. Install the splash shield under the vehicle.
    20.  
    21. Determine the capacity of the cooling system, then properly refill the system at the radiator opening with a 50/50 mixture of fresh coolant and distilled water.
    22.  
    23. Leave the recovery tank and radiator caps off to aid in bleeding the system.
    24.  
    25. On models with manual air conditioner controls, set the fan control to high and the temperature control to full warm. On models with automatic controls, set the temperature to 90° and the fan control to high. If the vehicle is equipped with a rear heater, set the controls to the same positions as the front controls.
    26.  
    27. Start the engine and allow it to idle until the thermostat opens (the upper radiator hose will become hot). The coolant level should go down, this is normal as the system bleeds the air pockets out of the system.
    28.  
    29. Refill the radiator with coolant.
    30.  
    31. Install the radiator cap.
    32.  
    33. Turn the engine OFF and check for leaks.
    34.  
    35. Lower the vehicle.
    36.  
    37. Fill the recovery tank to the FULL HOT level and replace the cap.
    38.  
    39. Allow the engine to cool completely and recheck the levels in both the radiator and the recovery tank.

      Click image to see an enlarged view

      Fig. Remove the radiator cap before draining the radiator



      Click image to see an enlarged view

      Fig. Be sure the rubber gasket on the radiator cap has a tight seal



      Click image to see an enlarged view

      Fig. The radiator petcock is located at the bottom of the right radiator tank



      Click image to see an enlarged view

      Fig. Engine coolant drain plug location. Some vehicles have 2 drain plugs, one on the left side and one on the right side



      Click image to see an enlarged view

      Fig. Left engine coolant drain plug location

    40.  

    Flushing & Cleaning The System



    1. Drain the cooling system completely as described earlier.
    2.  
    3. Close the petcock and fill the system with a cooling system flush (clean water may also be used, but is not as efficient).
    4.  
    5. Idle the engine until the upper radiator hose gets hot.
    6.  
    7. Allow the engine to cool completely and drain the system again.
    8.  
    9. Repeat this process until the drained water is clear and free of scale.
    10.  
    11. Flush the recovery tank with water and leave empty.
      CAUTION
      Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

    12.  
    13. Fill and bleed the cooling system as described earlier.

      Click image to see an enlarged view

      Fig. Periodically remove all debris from the radiator fins



      Click image to see an enlarged view

      Fig. Cutaway view of a typical cooling system flow

    14.  

     
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