Component Tests and General Diagnostics

WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOW FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP, STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.


1. Shut off the engine.
2. Open the hood and install protective fender covers.
3. When the engine is cool, carefully remove the radiator cap.
4. Adjust the radiator coolant level to 25 mm (1 inch) below filler neck before testing.





5. Attach the pressure pump and gauge to the adapter fitting and pressurize the cooling system to 103 kPa (15 PSI).





6. Inspect the cam lock flanges on both sides of the filler neck for maximum cap engagement.
7. Pressure should be held between 97 and 124 kPa (14 and 18 psi) and should not drop during this time.

If the system holds pressure, proceed to Step 9.

If the pressure drops, check for leaks at the engine to heater core hoses, engine to radiator hoses, bypass hose, water valve hose (if applicable), thermostat housing gasket, radiator, water pump and heater core, etc. Also refer to engine system checks if a leak cannot be located in the cooling system. Correct any leaks found and recheck the system.

8. Release the system pressure by loosening the Mini Cap Adapter 014-R1071. Check the coolant level. Replenish as necessary with the correct coolant solution.
9. Check the radiator overflow hose for any obstructions which may block the flow of coolant either to or from the radiator coolant recovery reservoir.
10. Conduct the Radiator Cap/Pressure Relief Cap Pressure Test.