Cooling System Leak Testing Charge Air Cooling

Special Tools

Warning: To avoid being burned, do not remove the charge air coolant cap while the system is hot. The cooling system will release scalding fluid and steam under pressure if charge air coolant cap is removed while the system is still hot.

Note: Ensure the intercooler system is cool and that the pump is not ON.

1. Remove the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement for the 4.4L engine.




Note: It is normal to have a very small pocket of air at the top of the system below the fill cap on a properly filled charge air cooling system.

2. Remove the charge air coolant cap.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the GE-47844 onto the charge air cooler cap port and tighten the bolts to 10 N·m (89 lb in).
4. Use the J 24460-01 with GE-47844 in order to apply pressure to the cooling system. Do not exceed 34 kPa (5 psi).
5. The cooling system should hold 34 kPa (5 psi) at least 2 minutes. Observe the gage for any pressure loss.
6. Repair any leaks as required.
7. Remove the GE-47844 from the charge air cooler cap port.



8. Install the charge air cooler cooling fill cap.
9. Ensure the charge air cooler cooling fill cap is installed in the proper orientation:

•	The alignment boss (1) is at the rear of the charge air cooler manifold.

•	The alignment boss (2) is at the front of the charge air cooler cooling filling cap.




10. Install the charge air coolant cap bolts and tighten to 10 N·m (89 lb in).
11. Install the manifold sight shield. Refer to Intake Manifold Sight Shield Replacement for the 4.4L engine.

Cooling System Leak Testing Powertrain

Special Tools

Warning: Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders, and the person removing the cap. Serious bodily injury may result. Flammable antifreeze, such as alcohol, is not recommended for use at any time. Flammable antifreeze could cause a serious fire.

Warning: In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon.

1. Remove the pressure cap.
2. Test the operation of the pressure cap. Refer to Pressure Cap Testing.
3. Wash the pressure cap mating surface with water.



4. Use the J 24460-01  (1) with J 42401  (2) in order to apply pressure to the cooling system.

Do not exceed the pressure cap rating.

5. The cooling system should hold the rated pressure for at least 2 minutes.

Observe the gage for any pressure loss.

6. Repair any leaks as required.