Cooling System, Pressure Test

PARTS REQUIRED: Description Part No.

Expansion tank cap (white) 1357776-2

SPECIAL TOOLS: Pressure tester 9985496-0





Warm-up engine

Warm-up engine until thermostat opens. Turn off engine.

Temporarily install white expansion tank cap (P/N 1357776-2).

Connect pressure tester, using T-piece, to small hose connected between radiator and expansion tank.

Increase pressure to approx. 90-95 kPA (13.0-13.8 psi).


Visually inspect the following areas for active coolant leakage (droplets):

1. Sealing ring, pump-cylinder head, no active coolant leakage allowed.
2. Gasket on cylinder block, no active coolant leakage allowed.
3. Drain hole from shaft seal. A quantity of one (1) drop per minute (under pressure) is allowed and considered normal. Anything exceeding this means the pump must be replaced. Stains on the pump housing are not cause for replacement unless the rate of coolant loss exceeds the standard.
4. Return pipe from car heater, no active coolant leakage allowed.
5. Connection to lower radiator hose, no active coolant leakage allowed.


Corrective action:

1. Replace seal.
2. Replace gasket.
3. Install new water pump, incl. gaskets.
4. Install new gaskets.
5. Tighten/replace hose clamp or hose as required. Remove any corrosion.