Cooling System Pressure Relief Testing

COOLING SYSTEM PRESSURE RELIEF TESTING

WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, THE COOLING SYSTEM BUILDS UP PRESSURE. TO PREVENT SCALDING OR OTHER INJURY, THE PRESSURE CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT AND/OR UNDER PRESSURE.

CAUTION: Vehicles equipped with 2.0L/2.4L engines use a different pressure cap than vehicles equipped with 2.7L engines. The pressure caps are NOT interchangeable. Verify proper pressure cap part number.

Fig. 30 Cooling System Pressure Cap to Filler Neck:

The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at the filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69 - 124 kPa (10 - 18 psi), and hold pressure at 55 kPa (8 psi) minimum.

There is no need to remove the pressure cap at any time except for the following purposes:
^ Check and adjust coolant freeze point
^ Refill system with new coolant
^ Conducting service procedures
^ Checking for leaks

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE. WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS, PUSH DOWN ON THE CAP AND REMOVE IT COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED.