Pressure Test

1. Turn the engine OFF.
2. Check engine coolant level and reinstall radiator cap.

WARNING: NEVER REMOVE THE RADIATOR CAP OR VENT PLUG 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, RADIATOR COOLANT RECOVERY RESERVOIR OR VENT, USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP OR VENT PLUG FROM THE VEHICLE. WAIT UNTIL THE ENGINE HAS COOLED. THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST 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 IT.

3. Disconnect the electrical connector from the water temperature indicator sender unit. Remove the water temperature indicator sender unit from the engine.

NOTE: With the radiator cap installed and the cooling system pressure relieved, only a small amount of coolant will be lost when the water temperature indicator sender unit (10884) is removed.

4. Install the adapter fitting from Rotunda Radiator/Heater Core Pressure Tester 014-R1072 or equivalent (male thread on one end and 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.

5. Disconnect radiator overflow hose (8075) from the radiator. Install a separate hose, making sure hose is firmly installed on the radiator overflow nipple and is in good condition. Insert the free end of the hose into a container of water.
6. Attach the pressure pump and gauge to the adapter fitting and pressurize to the lower limit.

No bubbles should appear in water container. 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 limit of the radiator cap.

Replace any radiator cap that exceeds the specified upper limit pressure without discharging bubbles.

7. If the pressure relief cap does not hold pressure remove and wash the radiator cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the filler neck.

Then inspect the cam lock flanges on both sides of the filler neck for maximum radiator cap engagement.

8. Pressurize the cooling system as described in Step 6 (using a radiator 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.

CAUTION: If the pressure drops, check for leaks at the engine-to-heater core hoses, engine-to-radiator hoses, bypass hose, water valve hose (if applicable), water hose connection gasket (8255), radiator and heater core, etc. Also refer to engine system checks if a leak cannot be located in cooling system. Any leaks which are found must be corrected and system rechecked or possible damage to the vehicle may occur.

If the system holds pressure, proceed to Step 9.

9. Release system pressure by loosening the radiator cap and remove the adapter. Re-install the water temperature indicator sender unit. Check engine coolant level and replenish if necessary with a 50/50 mixture of Premium Cooling System Fluid E2FZ-19549-AA or -B (in Oregon, F5FZ-19549-CC), recycled coolant or equivalent meeting Ford specification ESE-M97B44-A and water.