Component Tests and General Diagnostics

TOOL REQUIRED:
J 24460-01 Cooling System Tester or equivalent.

CAUTION: Pressures above 138 kPa (20 psi) should not be used when testing the cooling system. Pressures over 138 kPa (20 psi) will damage the radiator.





ON-VEHICLE
^ You can pressure test the aluminum plastic radiator with a common pump and gage, such as J 24460-01 or equivalent. With the system at a cool temperature, remove the radiator cap, connect the gage, and apply normal system operating pressure. Do not exceed 138 kPa (20 psi). Watch the gage needle for an indication of a leak, and examine the radiator and other cooling system parts for signs of escaping coolant.
^ Repair all hose and hose connections as required. Also check radiator cap to ensure that it will maintain the correct pressure.
^ If the radiator is found to be leaking during the pressure test, mark the leak area so that it is easily found once the radiator has been removed from the vehicle.

CAUTION: Do not use boil out tanks or vats or other tanks that have been used for copper and brass radiators. The flux, acid, and caustic cleaners remaining in these tanks will attack the aluminum and cause radiator failure. A separate test tank containing clean water is strongly recommended for servicing aluminum plastic radiators.





OFF-VEHICLE
1. Install test fittings or rubber test caps in the inlet and outlet necks and seal the oil cooler fittings with metal plugs to protect the cooler and keep the fluid from running out.
2. Attach pressure tester and gradually apply air pressure until 138 kPa (20 psi) is attained. Do not exceed 138 kPa (20 psi). Check pressure gage to see if there is a pressure loss. To ensure that there are no small leaks, run water over the repair area and look for bubbles. (A mild detergent is very helpful.) If a large water tank is available, the radiator can be submerged, and a check for air bubbles can be made.