Test Procedures

Visual Inspection

1. Check for leakage at:
   • All hoses and hose connections
   • Radiator seams, radiator core and radiator draincock
   • All block core plugs and drain plugs
   • Edges of all cooling system gaskets
   • Transmission oil cooler fittings
   • Vehicle heating system components
   • Water pump

2. Examine oil dipstick for evidence of coolant in engine oil.

3. Check radiator for evidence of oil in coolant (leakage at transmission oil cooler).

   Install cooling system analyzer to assist in testing the cooling system. Follow the manufacturer's recommended connections and testing procedures.

Coolant Condition and Protection Check

Cooling System Pressure Test

Tools Required:

• Rotunda Radiator/Heater Core Pressure Tester 021-00012
• Rotunda Battery and Anti-Freeze Tester 021-00046

1. Turn the engine OFF.

    WARNING: NEVER REMOVE THE RADIATOR PRESSURE CAP 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, USE EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST PRESSURE STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.

   NOTE: If the coolant is to be replaced, the remainder of this procedure may be omitted.

2. Check coolant for dirty or rusty appearance. Dirty or rusty coolant requires replacement to protect the cooling system from corrosion damage. Replace the coolant. Refer to Coolant Replacement.

   If coolant condition is satisfactory, check coolant concentration for proper protection level. Use a Rotunda Battery and Anti-Freeze Tester 021-00046 or equivalent, or a Hydrometer for testing. Maintain a protection level of at least -30°C (-20°F) to preserve anti-rust corrosion protection and ensure proper engine operating temperature. If concentration level is low, partially drain the cooling system by opening the radiator draincock or by partially removing the lower radiator hose. Secure the draincock or hose clamp and add 100 percent concentration of Premium Cooling System Fluid E2FZ-19549-AA (ESE-M97B44-A and ESE-M97B43-A) or equivalent to obtain the recommended protection level. Wet the rubber sealing surface of the radiator pressure cap before installing the cap tightly on the radiator.

   Coolant Specification: Use only a permanent-type coolant such as Premium Cooling System Fluid E2FZ-19549-AA (ESE-M97B44-A and ESE-M97B43-A) (in Canada, Motorcraft CXC-8-B) or equivalent.

3. Disconnect the electrical connector from the coolant temperature sending unit and remove the temperature sending unit from the engine.

   With the radiator pressure cap installed and the cooling system pressure relieved, only a small amount of coolant will be lost when the sending unit is removed.

4. Install the adapter fitting from Rotunda Radiator/Heater Core Pressure Tester 021-00012 or equivalent (male thread on one end, and a hose connector on the other end to accommodate the tester hose) tightly into the intake manifold or cylinder head in place of the sending unit.

5. Disconnect radiator overflow hose 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 overflow hose into a container of water.

6. Attach the pressure pump and gauge to the adapter fitting and pressurize the cooling system to the cap lower limit as shown in the test chart.

   No bubbles should appear in the water container when the system is pressurized to the lower limit. 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 pressure cap.

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

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

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

   NOTE: Small amount of "weeping" from water pump bleed hole is normal.

8. Pressurize the cooling system as outlined in Step 6 (using a radiator pressure cap that operates within the specified upper and lower pressure limits) and observe the gauge reading for approximately two minutes. Refer to Specifications . Pressure should not drop during this time.

   RESULTS: 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), thermostat housing gasket, 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.

   If the system holds pressure, proceed to Step 9.

9. Release system pressure by loosening the radiator pressure cap and remove the adapter. Install the temperature sending unit, check coolant level and replenish, if necessary, with the correct coolant solution.

Radiator Cap Pressure Test

Tools Required:

• Rotunda Radiator/Heater Core Pressure Tester 021-00012

1. Remove radiator pressure cap from radiator filler neck following outlined precautions.

   NOTE: The adapter is designed to accept both deep and shallow neck radiator pressure caps.

2. Use water to clean the cap in the area of the rubber seal and the vacuum relief valve. Refer to Cleaning and Inspection for procedure. Immerse the radiator pressure cap in water and install on the shallow filler neck of the Rotunda Radiator/Heater Core Pressure Tester 021-00012 or equivalent.

   NOTE: The filler neck seal is reversible so that it may be used on either a deep or shallow radiator filler neck. It will also fit either end of the radiator pressure cap pressure test adapter.

3. Immerse the filler neck seal in water and install in the filler neck adapter.

4. Install the filler neck adapter with filler neck seal on the deep filler neck end to the radiator pressure cap pressure test adapter.

5. Connect the female quick connect fitting of the pressure test pump to the male quick connect fitting of the filler neck adapter.

   NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will result.

6. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained.

7. Release the pressure by turning the pressure relief screw counterclockwise. Then, tighten the pressure relief screw and repeat Step 6 (at least twice) to ensure the pressure test reading is repeatable within the acceptable gauge reading limits of the radiator pressure cap and is not erratic. Refer to Specifications .

8. If the pressure test gauge readings are not within the acceptable gauge reading limits, replace the radiator pressure cap. If the pressure test gauge readings are within the acceptable gauge reading limits, perform the Cooling System Pressure Test.