How to drain cooling system - 2002 Dodge Caravan

Cooling System Draining and Filling (Static Fill)

Draining Procedure

Warning! In order to avoid personal injury, do not remove the cap or open the cooling system drains from a hot system. Allow the system to cool first.


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ImportantA 7.6 liter (8 qt) coolant container will be needed.

1. Place the coolant container under the radiator drain **** located at the bottom of the right radiator end tank.
2. Open the drain **** and drain the coolant. A small amount of coolant will drain from the system.


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3. Remove the surge tank cap from the surge tank and the coolant will drain from the system.


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4. For LE5 and LAT vehicles, if the engine block needs to be drained, a drain bolt is located near the bottom of the water pump assembly.
5. Inspect the coolant.
6. 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 Coolant System Flushing .

Filling Procedure

Caution! All entrapped air must be purged from the powertrain cooling system before the final coolant level can be determined. Proper coolant level is critical to avoid engine damage.
ImportantThe vehicle must be level when filling the cooling system.

1. Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean water to the coolant surge tank. Fill the cooling system as indicated below:
• For LE5/LAT vehicles when the engine block is not drained, add 3.5 liters (3.7 qts)
• For LE5/LAT vehicles when the engine block is drained, add 6 liters (6.3 qts)
• For LZ4/LY7 vehicles, add 5 liters (5.3 qts)

2. Start the engine and check for leaks.
3. Run the engine and cycle the vehicle from idle to 3,000 RPM in 30 second intervals until the engine cooling fan comes ON, the engine cooling fan turns ON at approximately 102°C (216°F). Repeat this process twice before the engine is turned OFF.
4. Return the engine to idle, and idle for 30 seconds, then turn the engine OFF.
5. Allow the vehicle to cool, before adding additional coolant.
ImportantThe level in the surge tank will return into the cold fill range once the vehicle cools.

6. Add additional coolant to the surge tank until the level is approximately 13 mm (0.5 in) above the surge tank seam.
7. Install the coolant surge tank cap.
8. Hope this helps.

Open radiator drain & coolant cap

Drain coolant----close rad drain & refill

50% Coolant 50% Distilled water

Thermostat - 3.0L (2V) Removal and Installation

1. Partially drain the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
2. Remove the three thermostat housing bolts. Fig. 25: Removing Thermostat Housing Bolts
   Courtesy of FORD MOTOR CO.
   
3. Remove the thermostat O-ring seal.
   • Inspect the sealing surfaces. Fig. 26: Removing Thermostat O-Ring Seal
     Courtesy of FORD MOTOR CO.
     
4. To install, reverse the removal procedure.

Thermostat - 3.0L (4V) Removal and Installation

1. Raise and support vehicle. For additional information, refer to JACKING & HOISTING .
2. Remove the front splash shield. For additional information, refer to FRONT END BODY PANELS .
3. Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
4. Remove the cooling tube bolt. Fig. 27: Removing Cooling Tube Bolt
   Courtesy of FORD MOTOR CO.
   
5. Lower the vehicle.
6. Remove the radiator upper cooling tube bolt. Fig. 28: Removing Radiator Upper Cooling Tube Bolt
   Courtesy of FORD MOTOR CO.
   
7. Disconnect the upper radiator hose and engine vent hose. Fig. 29: Disconnecting Upper Radiator Hose And Engine Vent Hose
   Courtesy of FORD MOTOR CO.
   
8. Remove the two bolts, and separate the radiator tube from the thermostat housing. Remove the thermostat. Fig. 30: Removing Bolts And Separating Radiator Tube From Thermostat Housing
   Courtesy of FORD MOTOR CO.
   
9. To install, reverse the removal procedure.

There are several methods for flushing the cooling system on ALL engine cooling systems. Time honored is drain the radiator (drain ****). Fill with fresh water and run engine to operating temperature until cooling fans turn on. Drain cooling system again. Refill with 50-50 coolant. Another method is purchasing a "T" vlave (coolant flush/service kit) from Autozone, PepBoys, NAPA, O'Reilys, CarQuest, etc.). This "T" valve is installed in one of the heater hoses & attached to a garden hose. Remove the radiator cap & turn on the water supply to the garden hose. Let water run until flush water is 'clear'. Remove garden hose from T valve & refill radiator with pure coolant until the T valve drainage turns green/orange. Install T valve cap... DONE!

1. Drain the cooling system.
2. Remove the engine cover.
3. Disconnect the Inlet hose from the housing.
4. Remove the thermostat housing bolts (A), thermostat housing (B), and the Thermostat (D).
5. Clean the gasket mating surfaces and the housing and intake port.

To Install:

1. Install the Thermostat (D).
2. Install the thermostat housing (B) with a new gasket (C) and torque the bolts (A) to 15 ft-lb (20 Nm).
3. Connect the inlet hose.
4. Install the engine cover.
5. Refill the cooling system.

To Drain:
NOTE: Draining the cooling system with the pressure cap installed will siphon the coolant from the overflow tank.

1. Raise and support the vehicle.
2. Open the radiator drain **** and drain the coolant into a drain pan.
3. Empty and wash out the coolant reservoir with soap and water.
4. Inspect the coolant if discolored flush the system before refilling.

To Fill:
CAUTION
Follow the procedure below to insure the coolant is at the proper level. A coolant level that is too high or too low could cause engine damage.

1. Close the radiator drain **** and lower the vehicle.
2. Slowly fill the cooling system with a 50/50 mixture of DEX-COOL antifreeze and clean drinkable water.
3. Install the coolant pressure cap and start the engine.
4. Run the engine at 2,000-2,500 RPM until the engine reaches normal operating temperature than let the engine idle for 3 minutes.
5. Turn the engine off and let the engine cool off.
6. Top off the coolant and check the concentration of the coolant using the (J 26568) coolant and battery tester.

1. Drain the cooling system. Refer to Draining and Filling Cooling System (LS4 Static Fill) Draining and Filling Cooling System (LZE, LZ4, LZ9 Static Fill) Draining and Filling Cooling System (9C1, 9C3 Static Fill) Draining and Filling Cooling System (LS4 GE 47716 Fill) Draining and Filling Cooling System (LZE, LZ4, LZ9, 9C1, 9C3 GE 4771 Fill).
2. Loosen the water pump pulley bolts.
3. Remove the drive belt.
4. Remove the water pump pulley bolts and pulley.
5. Remove the water pump bolts.
6. Remove the water pump and gasket.
7. Clean the water pump mating surfaces
   1. Position a NEW water pump gasket and the water pump to the engine front cover. Notice: Refer to Fastener Notice.
   2. Install the water pump bolts. Tighten the bolts to 10 Nm (89 inch lbs.) .

1. Install the water pump pulley and bolts.
2. Install the drive belt.
3. Tighten the water pump pulley bolts. Tighten the bolts to 25 Nm (18 ft. lbs.) .
4. Fill the cooling system. Refer to Draining and Filling Cooling System (LS4 Static Fill) Draining and Filling Cooling System (LZE, LZ4, LZ9 Static Fill) Draining and Filling Cooling System (9C1, 9C3 Static Fill) Draining and Filling Cooling System (LS4 GE 47716 Fill) Draining and Filling Cooling System (LZE, LZ4, LZ9, 9C1, 9C3 GE 4771 Fill).
5. Inspect for leaks.

Hope this helps

The capacity is 2- 2.5 gallons of coolant.
I would drain the cooling system from the radiator drain plug.

I would follow the owners manual for the instruction and fluid levels.

Not a problem if you can't find it...remove the lower hose at the radiator. it's faster and easier...half the drains don't work right anyhow...

its a pitcock facing the cab bottom of the radiator, plastic flat. once you find the pitcock just put a bucket underneath and turn it.then refill. if you want to flush(run fluid thru to clean it out) the radiator id suggest taking it in. you dont have to flush it every time you change the coolant out.

I Suspect that you have AIR in your COOLING SYSTEM Fallow Procedures BELOW to Insure there is NO AIR IN COOLING SYSTEM


Draining and Filling Cooling System

Draining Procedure

Important: Do NOT add any engine coolant supplement sealant pellets to the cooling system. Drain and refill the engine cooling system every 5 years or 240,000 km, (150,000 mi) , whichever occurs first.

1. Park the vehicle on a level surface.
2. Remove and clean the coolant recovery reservoir.

Caution: Refer to Radiator Cap Removal Caution in Service Precautions.

1. Remove the radiator cap when the engine is cool:

3.1. Slowly rotate the cap counterclockwise to the detention tab. Do not press down while rotating pressure cap. 3.2. Wait until any residual pressure, indicated by a hissing sound, is relieved. 3.3. After all hissing stops, press down on the radiator cap and rotate the cap counterclockwise in order to remove the cap.
Important: Recover and store used coolant in a used coolant holding tank and submit the used coolant for recycling on a regular basis. Do NOT pour used coolant down the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol into the sewer system or ground water is both illegal and ecologically unsound.

1. Place a drain pan under the radiator drain valve in order to collect all of the used coolant.
2. Open the radiator drain valve located at the bottom of the radiator tank. If only partial cooling system draining is required, drain enough coolant to perform the procedure.
3. Open the air bleed valve on the thermostat housing 2 full turns
   1. Open the air bleed valve above coolant pump 2 full turns.
   2. Place a drain pan under the engine block drains in order to collect the used coolant.Important: Allow the coolant to drain completely.
      
      
      1. Remove both of the engine block drains.
      • The front left engine block drain is located between the starter motor and the engine oil filter.
      • The rear right engine block drain is located near the crankshaft position sensor.
      Filling Procedure
      Reinstall the engine block drains
      
   3. Close the radiator drain valve,
      1. Install the coolant recovery reservoir. Notice: When adding coolant, it is important that you use GM Goodwrench DEX-COOL or HAVOLINE DEX-COOL coolant. If Coolant other than DEX-COOL or HAVOLINE DEX-COOL is added to the system the engine coolant will require change sooner; at 50,000 km (30,000 mi) or 24 months.
      2. Slowly add a 50/50 mixture of GM Goodwrench DEX-COOL or HAVOLINE DEX-COOL and clean, drinkable water to the radiator until the coolant level is at the base of the radiator fill neck.
      3. Wait for 2 minutes and reinspect the level of the coolant in the radiator. If necessary, add coolant to the radiator until the coolant level is at the base of the radiator fill neck.
      4. Install the radiator cap.Ensure that the radiator cap arrow points toward the radiator overflow tubeImportant: The air bleed valves are brass. Do NOT over-tighten the air bleed valves.
         
         
         1. Close the air bleed valve above the coolant pump.
            1. Close the air bleed valve on the thermostat housing.
            2. Fill the coolant reservoir with a 50/50 mixture of GM Goodwrench DEX-COOL or HAVOLINE DEX-COOL and clean, drinkable water. Caution: Refer to Radiator Cap Removal Caution in Service Precautions. Important: If the coolant temperature indicator turns ON, turn the engine OFF immediately and allow the engine to cool. Do NOT remove the radiator cap.
            3. Start the engine and allow the engine cooling fan to cycle on and off 3 times. If the low coolant indicator does not turn OFF and the coolant level is above the Full Cold mark on the coolant recovery reservoir, refer to Engine Coolant Temperature Gage Inaccurate or Inoperative.
            4. Turn off the ignition.
            5. Allow the engine to cool.
            6. Ensure that the engine coolant concentration is sufficient.