Pressure Test Cooling System

RG6557-UN-20JAN93

Test Coolant Cap

RG6558-UN-20JAN93

Testing Cooling System

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Test Coolant Tank Filler Cap

1. Remove coolant tank filler cap and attach to D05104ST Tester as shown.

2. Pressurize cap to 100 kPa (1.05 bar) (15 psi). Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable.

   If gauge does not hold pressure, replace filler cap.

3. Remove the cap from gauge, turn it 180° and retest cap. This will ensure that first measurement was correct.

Testing Cooling System

NOTE: Engine should be warmed up to test overall cooling system.

1. Allow engine to cool down, then carefully remove coolant tank filler cap.

2. Fill coolant tank with coolant to the normal operating level.

3. IMPORTANT: DO NOT apply excessive pressure to cooling system, doing so may damage radiator and hoses.

   Connect gauge and adapter to coolant tank filler neck. Pressurize cooling system to 100 kPa (1.05 bar) (15 psi).

4. With pressure applied, check all cooling system hose connections, coolant tank and overall engine for leaks.

   If leakage is detected, correct as necessary and pressure test system again.

   If no leakage is detected, but the gauge indicated a drop in pressure, coolant may be leaking internally within the system or at the block-to-head gasket. Have your servicing dealer or distributor correct this problem immediately.