Non-Trouble Code Procedures

Leak Testing Procedure (On Vehicle)

- Tools Required
- J24460-01
- J24460-92

Caution:
- Refer to Radiator High Pressure/Temperature Caution in Service Precautions.
- Refer to Hot Radiator Cap Caution in Service Precautions.





1. After the system has cooled, remove the surge tank pressure cap. Refer to Pressure Cap Description.
2. Connect the cooling system tester J24460-01 and the J24460-92 to the surge tank.
3. Apply normal system operation pressure. Do not exceed 138 kPa (20 psi).
4. Watch the gauge needle for an indication of a leak. Examine all cooling system connections and components, including the radiator and the heater core, for leaking coolant.
5. Tighten the hose connections or repair as required.





6. Check the surge tank cap with the J24460-01 and the J24460-92 in order to ensure the cap maintains the correct pressure.
7. If the radiator leaks during the pressure test, mark the leak area so the leak can be located once the radiator has been removed from the vehicle.

Pressure Cap Testing

- Tools Required
- J24460-01 Cooling System Tester

Caution: As long as there is pressure In the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator without causing the solution to boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the solution to boil instantaneously -possibly with explosive force - spewing the solution over the engine, fenders and the person removing the cap.

1. Remove the surge tank cap when the engine is cool:
1.1. Slowly rotate 1/4 turn and stop. Do not press down while the cap.
1.2. Wait until any residual pressure (indicated by a hissing sound) is relieved.
1.3. After all hissing stops, continue to rotate the cap counterclockwise until the cap is removed.
2. Wet the surge tank cap gasket with water.
3. Wash off any sediment from the sealing surface.
4. Install the cap to the J24460-01.
5. Use the plunger handle of the J24460-01 in order to increase the pressure as specified on the cap.
6. Note the rate of decrease in the pressure.
7. The specified reading of the pressure should remain within the corresponding pressure scale for more than 10 seconds.
8. Replace the surge tank cap if it does not maintain the pressure for more than 10 seconds.