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 Cooling System Pressure Tester  (1) with J 42401 Radiator Cap and Surge Tank Test Adapter  (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.

Cooling System Leak Testing Charge Air Cooling

Special Tools

7000081 Tech 2 Kit

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.

Note: The charge air cooling system is leak tested visually with the charge air cooler pump ON.

1. Connect the 7000081 Tech 2 Kit to the vehicle.
2. Command the charge air cooling pump ON using the 7000081 Tech 2 Kit .
3. Run the pump for at least 2 minutes. Observe the charge air cooling system hoses and components for any sign of coolant leakage.
4. Repair any leaks as required. Refer to the appropriate repair procedure.