Pressure Test - Coolant Expansion Tank Systems

Pressure Test - Coolant Expansion Tank Systems

WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.

NOTE: Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

1. Turn the engine OFF.
2. Remove the pressure relief cap. Top off the radiator as needed. Fit the pressure tester to the radiator fill neck.

3. CAUTION: Do not pressurize the cooling system beyond 138 kPa (20.0 psi) or cooling system components can be damaged.

NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading will result.

Pump the cooling system to a maximum of 138 kPa (20.0 psi) and hold for 2 minutes. If the pressure drops within this time, inspect for leaks and repair as necessary.
4. If no leaks are found and the pressure drops, the leak may be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as necessary.
5. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant.

Cap
1. Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap if necessary.
2. Fit the pressure relief cap to the Radiator/Heater Core Pressure Tester Kit using the correct adapter.

3. NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading will result.

Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release the pressure and repeat the test. Install a new pressure relief cap if the pressure is not within specification.