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Old 08-02-2011, 10:27 PM   #1
les1234
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Default How to: Easy Coolant Change - Ion

I just changed the antifreeze on my 2005 Saturn Ion, the procedure was easy and takes about 2 hours. The steps I followed are detailed below.

**Should be in the How-to Library, but I don't have permission to create a thread there**



Cooling System 2004 ION
Capacity: Rad 1.75L, (Engine+ Heater) 4.75L Tot = 6.5L Surge Tank 1 L , Total system = 7.5L


Need 1 Gal Prestone Orange Dexcool Pure Antifreeze ($20 CT), 16 L dehumidifier (or distilled) water, penetrating oil, small mini mallet, >1.5 wide, 6 long hose or small funnel with hose wide hose (to collect coolant from Rad support bung when petcock is opened), 500 ml measuring cup, 12L 4 high rectangle pan or AL roasting pan ( only get 3.75L coolant when rad is drained), waterpump pliers, needlenose pliers, siphon if reqd to siphon tank otherwise not reqd, Grease for petcock /housing interface end)



Method: Spray penetrant oil on petcock/ housing interface and tap around well with small mallet. Let sit for 5 min and repeat. Use waterpump pliers on interface to crack petcock open, then use needlenose pliers to turn first thread, then finger turn to open, drains in 1-2 min. Tie hose to rad rubber bung. Need measuring cup and 12L rectangle pan to collect 2.75L mixture. If reqd, siphon out 1 L from surge tank.



Drain Remove Mixt Remain Antifreeze Remain Water .
Drain1 Original coolant 3L (37C) 2.25L 2.25L Add 3L water SLOWLY, can see tank coolant drains into rad and auto displaces rad air. Press both rad hoses to burp system and circulate liq. Heater on full at feet. Run engine taking up to 3500rpm 15 sec then down to idle, repeat 3 times/cycle. When upper rad hose feels hot ~ 6 min. turn engine off. Cool in 10 min with breeze or fan, Open drain cock, drains thru bung hose in 1-2 min. Finger tighten petcock so that protrusion is in horiz position.



Squeeze hoses immed when engine off (should we squeeze while engine is running because once engine is off, squeezing only mixes with rad 1.75L and not remaining 1.75L in engine/heater . Warm coolant -29C cool coolant -37C No need to swap pure antifreeze with final coolant mixture. Run car for 1 week, check freezing temp when cool. If reqd, drain rad and add balance of jug1.25 L pure antifreeze. Petcock finger tight
Each cycle 20 min x 5 =100 min + 10 min setup + 10 min cleanup =120 min = 2hrs say 2 hours.
Old coolant looked like new with miniscule negligible amount of black and Al particulate.

Note Expansion Surge Tank is only for hot expanded coolant extra volume. If coolant does not get very hot during flushing cycle, tank coolant does not mix with engine/rad coolant; hence need to manually squeeze both rad hoses to mix tank and circulating coolant. Will only mix rad + tank coolant with engine shut off, could try squeezing when engine is upper rad hose is hot to mix all coolant)
Attached Images
File Type: jpg AntifreezeTable.jpg (108.4 KB, 167 views)
File Type: jpg Rad Petcock6.jpg (151.0 KB, 174 views)
File Type: jpg Rad Petcock Housing.JPG (141.8 KB, 167 views)
File Type: jpg Rad Petcock7.jpg (123.1 KB, 166 views)

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Old 08-03-2011, 05:35 AM   #2
2006 ion2
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Location: Da U.P, EH!
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2007 ION-2 Sedan
Default Re: How to: Easy Coolant Change - Ion

nice, except one thing. the petcock is plastic. be careful using penetrating oil on plastic, as a lot of them will eat plastic. this proves there is no reason not to use the petcock when changing the coolant.

...
2007 Saturn Ion 2
2003 Chevrolet venture lt

trifecta dealer for the U.P. and WI. There is no two door ion. Proudly driving one of the last saturns produced before gm killed the brand.

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Old 08-04-2011, 03:23 PM   #3
les1234
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Default Re: How to: Easy Coolant Change - Ion

Gunk penetrating oil had NO effect on my radiator petcock. I double checked with William Vanover, Liquid Wrench Quality & Customer Service Manager, 600 Radiator Road, Indian Trail, NC 28079 (email rscwebmail@gmail.com). His answer as to whether Gunk penetration oil will attack petcock hard plastic is NO (see attachment below from his email reply)

SKU Description Yes/No
L112 Penetrate No
L212 Lubricant No
L616 White Lithium No
L512 Dry Lube No
L711 Chain Lube No
M914 Silicon No

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Old 11-08-2012, 06:11 PM   #4
lgodave
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2003 ION-3 Sedan
Default Re: How to: Easy Coolant Change - Ion

Glad to hear this... considering I'd been assuming I'd need to "bypass" the petcock. (Others having suggested their "horror stories" of difficulty in removal)

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