Cooling System Leak Testing

ON-VEHICLE PRESSURE TESTING PROCEDURE

^ Tools Required
- J 24460-01 Cooling System and Cap Pressure Tester
- J 24460-92 Cooling System Tester Adapter

1. Inspect the connections of the coolant hoses for leaks. Tighten the clamps as required.

CAUTION: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boll instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.

CAUTION: Under some conditions, the ethylene glycol engine coolant is combustible. In order to help avoid being burned, do not spill the antifreeze or the coolant on the exhaust system or the hot engine parts.

2. Remove the surge tank cap.





3. Install J 24460-01 to the surge tank. Follow the instructions supplied with the J24460-01.
4. Pump J 24460-01 to 103 kPa (15 psi) by operating the plunger handle. Do not exceed 138 kPa (20 psi).
5. The pressure reading should remain within the corresponding pressure segment of the scale for about 2 minutes.
- If a measurable amount of pressure drops within two minutes, check for a leak.
- If there is a leak, remove the radiator. Replace the radiator. Refer to Radiator Replacement.