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Cooling System Pressure Test

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly.
Failure to follow these instructions may result in serious personal injury.
NOTE: The engine cooling system is filled with Motorcraft® Specialty Green Engine Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of the coolant. Failure to follow these instructions may damage the engine or cooling system.
NOTE: Motorcraft® Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade.
NOTE: Vehicles have the pressure relief cap on the degas bottle and no radiator cap.
  1. Turn the engine OFF.
  2. Check the engine coolant level. Adjust the coolant level as necessary.
  3. Attach the D-Gas Adapter to the degas bottle nipple and overflow hose. Install the Radiator Tester to the quick connect fitting of the D-Gas Adapter.
    Fig 1: Checking Cooling System Pressure Using Radiator Tester
    G07399033Courtesy of FORD MOTOR CO.
    4. NOTE: Do not pressurize the cooling system beyond the maximum pressure listed in the SPECIFICATIONS  table in this service information or cooling system components may be damaged.
    NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading will result.
  4. Slowly press the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained. If the pressure reading exceeds the maximum cap pressure listed in the specifications table, install a new pressure relief cap.
  5. If the system does not hold pressure, remove the pressure relief cap and wash in clean water to dislodge all the foreign material from the gasket.

    Check the sealing surface in the filler neck of the degas bottle for nicks or cuts. Install the pressure relief cap.

  6. Pressurize the engine cooling system as described in Step 4. Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.
  7. If no leaks are found and the pressure drops. the pressure relief cap may be leaking. Install a new pressure relief cap and retest the system.
  8. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as necessary.
  9. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to ENGINE SYSTEM - GENERAL INFORMATION article to diagnose the engine.
  10. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as necessary.
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