PINPOINT TEST A: Coolant Loss Tests

TEST CONDITIONS 

DETAILS/RESULTS/ACTIONS 

1. A1: COOLANT LOSS TEST 1 
   • DO NOT  remove the coolant expansion tank cap when the engine is hot. Failure to follow this instruction may result in personal injury.
   • Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine and/or cause personal injury.
   1. Perform a visual check for coolant leaks

      Is a coolant leak present?

      • Yes  : Rectify the leak as necessary. Refer to the relvent service information and fill and bleed the cooling system.
      • No  : GO to  A2.
2. A2: COOLANT LOSS TEST 2 
   WARNING:

   • DO NOT  remove the coolant expansion tank cap when the engine is hot. Failure to follow this instruction may result in personal injury.
   • Never, under any circumstances, remove the coolant expansion tank pressure cap while the engine is operating. To avoid having scalding hot water or steam blow out of the cooling system, use extreme care when removing the coolant expansion tank pressure cap from a hot cooling system. Wait until the engine has cooled, then wrap a thick cloth around the coolant expansion tank pressure cap and turn it slowly until the pressure begins to release, step back while the pressure is released from the system. When certain all the pressure has been released (still with a cloth) turn and remove the coolant expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine and/or cause personal injury.
   1. Remove the coolant expansion tank cap
   2. Check the coolant level. Add coolant as necessary
   3. Install the cooling system pressure test equipment
   4. Pressurize the cooling system to the coolant expansion tank cap lower limit
   5. Observe the pressure gauge reading for approximately two minutes (the pressure should not decrease during this time)

      Has the system pressure decreased?

      • Yes  : Rectify the leak as necessary. Refer to the relvent service information and fill and bleed the cooling system
      • No  : GO to  A3.
3. A3: COOLANT LOSS TEST 3 
   1. Release the system pressure and remove the pressure test equipment
   2. Check the coolant level. Add coolant as necessary
   3. Check the radiator overflow hose for any obstructions which may block the flow of coolant either to or from the coolant expansion tank.

      Is a blockage present?

      • Yes  : Clear the blockage. Refer to the relvent service information and fill and bleed the cooling system
      • No  : Verify the customer complaint