Pressure Test

1. Turn the ignition switch OFF.

WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN RADIATOR CAP SLOWLY TO THE FIRST PRESSURE STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL WITH A CLOTH), TURN AND REMOVE RADIATOR CAP.

2. Check engine coolant for dirty or rusty appearance. Dirty or rusty coolant requires replacement to protect the cooling system from corrosion damage. Replace the engine coolant if necessary.
3. If coolant condition is satisfactory, check coolant concentration for proper protection level. Use Rotunda Battery and Antifreeze Tester 014-R1060 or equivalent, or a Hydrometer for testing. Maintain a protection level of at least -30°C (-20°F) to preserve anti-rust corrosion protection and ensure proper engine operating temperature. If concentration level is low, partially drain the engine coolant by opening the radiator draincock (8115) or by partially removing the lower radiator hose (8286). Secure the radiator draincock or hose clamp and add 100 percent concentration of Premium Cooling System Fluid E2FZ-19549-AA or -B, in Oregon F5FZ-19549-CC, in Canada, Motorcraft CXC-8-B, recycled coolant, or equivalent meeting Ford specification ESE-M97B44-A to obtain the recommended protection level. Wet the rubber sealing surface of the pressure relief cap before installing the pressure relief cap.

NOTE: With the pressure relief cap installed and the cooling system pressure relieved, only a small amount of engine coolant will be lost when the water temperature indicator sender unit is removed.

4. Disconnect the electrical connector from the water temperature indicator sender unit (10884) and remove the water temperature indicator sender unit from the engine.
5. Install the adapter fitting from Rotunda Radiator/Heater Core Pressure Tester 014-R1072 or equivalent (male thread on one end, and a hose connector on the other end to accommodate the tester hose) tightly into the intake manifold (9424) or cylinder head (6049) in place of the water temperature indicator sender unit.
6. Disconnect radiator overflow hose (8075) from the radiator. Install a separate hose, making sure hose is firmly installed on the radiator overflow hose nipple and is in good condition. Insert the free end of the radiator overflow hose into a container of water.
7. Attach the pressure pump and gauge to the adapter fitting and pressurize the engine cooling system to the pressure relief cap lower limit as shown in Specifications. No bubbles should appear in the water container when the system is pressurized to the lower limit. If the system is satisfactory at the lower limit, gradually increase the system pressure until a slight stream of bubbles appears in the water container. This is the upper pressure limit of the radiator cap.
^ Replace any pressure relief cap that exceeds the specified upper limit pressure without discharging bubbles.
8. If the pressure relief cap does not hold pressure, remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the radiator filler neck. Then inspect the cam lock flanges on both sides of the filler neck for maximum pressure relief cap engagement.

CAUTION: If the pressure drops, check for leaks at the engine to heater water hoses, engine-to-radiator hoses, bypass hose, water valve hose (if applicable), water thermostat housing gasket, radiator and heater core and other connections. Also refer to Engine for engine system checks if a leak cannot be located in cooling system. Any leaks which are found must be corrected and system rechecked.

9. Pressurize the engine cooling system as described in Step 6 (using a pressure relief cap that operates within the specified upper and lower pressure limits) and observe the gauge reading for approximately two minutes. Pressure should not drop during this time.
^ If the system holds pressure, proceed to Step 10.
10. Release system pressure by loosening the pressure relief cap and remove the adapter. Install the water temperature indicator sender unit, check engine coolant level and replenish (if necessary) with the correct coolant solution.