Cooling System Leak Testing

Special Tools EN-24460-A Cooling System Pressure Tester GE-42401-A Radiator Cap and Surge Tank Test Adapter Equivalent regional tools: Special Tools

Warning

Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders, and the person removing the cap. Serious bodily injury may result. Flammable antifreeze, such as alcohol, is not recommended for use at any time. Flammable antifreeze could cause a serious fire.

Warning

In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon.

1. Remove the radiator surge tank cap.
2. Test the operation of the radiator surge tank cap. Radiator Surge Tank Cap Testing
3. Clean the radiator surge tank cap mating surface with water.

Cooling System Leak Testing — figure 1

4. Attach GE-42401-A Radiator Cap and Surge Tank Test Adapter (2) to the radiator surge tank.
5. Attach EN-24460-A Cooling System Pressure Tester (1) to GE-42401-A Radiator Cap and Surge Tank Test Adapter (2).
6. Apply pressure to the cooling system. Do not exceed the radiator surge tank cap pressure rating.
7. The cooling system should hold the radiator surge tank cap rated pressure for at least 2 minutes. Observe the gage for any pressure loss.
8. Repair any leaks as required.