Pressure Test

1. Shut the engine off.

WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP OR DEGAS BOTTLE CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN 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 PRESSURE RELIEF CAP OR DEGAS BOTTLE CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP OR DEGAS BOTTLE CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE PRESSURE RELIEF CAP OR DEGAS BOTTLE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.

2. Open hood and install protective fender covers.
3. When engine is cool, cautiously remove pressure relief cap or degas bottle cap.
4. Disconnect battery.
5. Adjust the radiator coolant level (fill or drain) to 25 mm (one inch) below the filler neck opening before testing. Wipe clean, and then wet the rubber sealing surfaces in the cap and filler neck before installing the radiator cap tightly on the radiator.
6. Disconnect the electrical connector from the coolant temperature sending unit and remove the temperature sending unit from the engine.

With the pressure relief cap installed and the cooling system pressure relieved, only a small amount of coolant will be lost when the sending unit is removed.

7. Using the adapter fitting from Rotunda Radiator Pressure Tester 014-R1072 or equivalent (male thread on one end, and a hose connector on the other end to accommodate the tester hose) tightly into the intake manifold or cylinder head in place of the sending unit.
8. Remove the radiator overflow hose from the overflow nipple. Install a separate radiator overflow hose firmly on the overflow nipple. Insert the free end of separate radiator overflow hose into container of water
9. Attach the pressure pump and gauge to the adapter-fitting and pressurize the cooling system to 69 kPa (10 psi).

No bubbles should appear in the water container when the system is pressurized to the LOWER LIMIT (69 kPa [10 psi]). If the system is satisfactory at the lower limit, gradually increase the system pressure until a slight stream of bubbles appears in the water container. This is the release pressure of the pressure cap.

Replace any pressure relief cap or degas bottle cap that has a release pressure that is greater than the specified UPPER LIMIT pressure (90 kPa [13 psi]) without discharging bubbles.

10. If the radiator relief cap or degas bottle cap does not hold pressure, remove and wash the pressure relief cap or degas bottle cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the radiator filler neck.

Inspect the cam lock flanges on both sides of the filler neck for maximum cap engagement.

11. Pressurize the cooling system as described in Step 6 (using a pressure relief cap and degas bottle cap that operate within the specified upper and lower pressure limits) and observe the gauge reading for approximately two minutes. Pressure should be held between 69 and 90 kPa (10 and 13 psi) and should not drop during this time.
12. 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 and heater core. Also refer to engine system checks if a leak cannot be located in the cooling system. Any leaks that are found must be corrected and the system checked again.

If the system holds pressure, proceed to next step.

13. Release the system pressure by loosening the pressure relief cap and removing the adapter. Install the water temperature indicator sender unit, check coolant level and replenish, if necessary, with the correct coolant solution.
14. Connect battery ground cable.

NOTE: When the battery has been disconnected and reconnected some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.