Cooling System Leak Testing (Pressure Test)
Special Tools
GE-42401-A Radiator Cap and Surge Tank Test Adapter
For equivalent regional tools, refer to Special Tools .
- Remove the pressure cap.
- Test the operation of the pressure cap. Refer to Pressure Cap Testing .
- Wash the pressure cap mating surface with water.
Install the GE-42401-2 pressure test adapter (1) to the coolant recovery reservoir (2) to plug the reservoir bleeder gallery.
Use a commercial cooling system pressure adapter (1) and moisten the rubber with coolant fluid.
Install the commercial adapter (1) to the GE-42401-3 adapter (2). Use a suitable underlay to be able to use enough force. Inspect the assembly for proper seat then.
Install the assembled adapters (3, 4) to the coolant recovery reservoir (5).
- Install a commercial cooling system pressure tester (1, 2) to the commercial adapter.
- Using the pressure tester apply pressure to the cooling system.
- Observe the gage of the pressure tester for any loss.
- The cooling system should hold the rated pressure for at least 2 minutes.
- Repair any leaks as required.
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.
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.
Do NOT exceed the pressure cap rating.