Cooling System Pressure Test (G1898875): Activation

WARNING: Since injury such as scalding could be caused by escaping steam or coolant, allow the vehicle cooling system to cool prior to carrying out this procedure.

NOTE: The following procedure will enable the cooling system to be pressure tested for condition and leaks. Stage 1 will check the expansion tank cap register seal and the cap for leaks. Stage 2 will check the entire cooling system.

NOTE: If the coolant expansion tank cap is found to be leaking, replace the cap.

Examine the coolant hoses for signs of cracking, distortion and security of the hose connections.
1. Remove the expansion tank cap, using the correct adaptor connect the cooling system pressure test kit to the cap.
1. Note the release pressure displayed on the expansion tank cap before applying pressure.
1. Slowly pressurize the expansion tank cap checking for leaks. Once the noted cap pressure is reached the pressure will be released through the cap.
Depressurize and remove the cooling system pressure test kit.
CAUTION:
- Make sure that the mating faces are clean and free of foreign material.
- Do not exceed 1.0 bar (15 psi) whilst pressurizing the cooling system.
NOTE: If the pressure continues to drop after the initial tolerance, there is a coolant leak.
1. Using the correct adaptor connect the cooling system pressure test kit to the vehicle expansion tank.
1. Slowly pressurize the cooling system until the pressure gauge reads 1.0 bar (15 psi).
1. Make sure the cooling system holds pressure for 5 minutes, note that a small pressure decay of approximately 0.15 bar (1 psi) over the first minute is normal.
Depressurize and remove the cooling system pressure test kit.
CAUTION: Correct installation of the coolant expansion tank cap can be obtained by tightening the cap until 3 audible clicks are heard.

Install the expansion tank cap.