Contents: Pressure testing of the cooling…⇩ Pressure testing of the sealed cap…⇩ Checking the Thermostat ⇩ Checking the radiator for leaks -…⇩
Pressure testing of the cooling system
WARNING: Never remove the coolant expansion tank pressure cap while the engine is running. To avoid being scalded by hot water or steam, use extreme caution when removing the coolant expansion tank pressure cap when the cooling system is warm. Wait until the engine has cooled, wrap the coolant expansion tank pressure cap in a thick cloth and slowly loosen it until pressure begins to release; step back while releasing pressure. Once you are sure that all pressure has been released and without removing the cloth, twist and remove the expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine, and/or personal injury.
1. Turn off the engine.
2. Open the hood and install the protective covers on the fenders.
3. Carefully remove the expansion tank sealing cap to relieve pressure in the cooling system. If necessary, add coolant to the expansion tank.
4. Install pressure testing equipment on the cooling system following the manufacturer's instructions. Replace the expansion tank pressure cap (if the expansion tank does not have pressure testing equipment installed).
5. Raise the pressure in the cooling system to the lower limit set for the expansion tank sealing cap.
6. Observe the pressure gauge readings for approximately two minutes. During this period of time, the pressure should not drop.
- If the system holds pressure, continue with step 7.
- If the pressure drops, check the entire cooling system for leaks. If you cannot find a leak in the cooling system, also refer to the engine system checks. Repair any leaks found and retest the system.
8. Check for a blockage in the radiator bypass hose that may be preventing coolant from flowing in/out of the expansion tank.
9. Perform the coolant expansion tank seal check described in this section.
Pressure testing of the sealed cap of the expansion tank of the cooling system
The text of the article was taken from the website: LRman.ru
WARNING: Never remove the coolant expansion tank pressure cap while the engine is running. To avoid being scalded by hot water or steam, use extreme caution when removing the coolant expansion tank pressure cap when the cooling system is warm. Wait until the engine has cooled, wrap the coolant expansion tank pressure cap in a thick cloth and slowly loosen it until pressure begins to release; step back while releasing pressure. Once you are sure that all pressure has been released and without removing the cloth, twist and remove the expansion tank pressure cap. Failure to follow these instructions may result in damage to the cooling system, engine, and/or personal injury.
1. Remove the sealing cap from the expansion tank of the cooling system.
2. Wash the cap with water in the area of the rubber seal and the relief valve. In accordance with the manufacturer's instructions, install the sealed expansion tank cap on the test equipment.
NOTE: If the test equipment pressure is raised too quickly, incorrect pressure readings may occur.
3. Slowly increase the pressure in the system until the pressure gauge readings stop increasing; record the highest pressure reading noted.
4. Release the pressure and repeat step 3 at least twice to ensure that the readings obtained are repeated and within the normal range.
5. If the pressure gauge readings are not within the normal range, install a new sealed cap on the expansion tank of the cooling system.
Checking the Thermostat
Remove the thermostat. For more information, refer to: Thermostat (303-03B Engine Cooling - 2.2L Duratorq - Td4, Removal and Installation).
Check for visual damage, record the thermostat opening temperature and immerse it in water. Heat the water until this temperature is reached. The thermostat should then begin to open. If the thermostat does not begin to open, install a new thermostat. For more information, refer to: Thermostat (303-03B Engine Cooling - 2.2L Duratorq - Td4, Removal and Installation).
If the thermostat begins to open, continue heating the water until the thermostat opens fully, 5.8 mm or more from the seat. If the thermostat does not open fully, install a new thermostat. For more information, refer to: Thermostat (303-03B Engine Cooling - 2.2L Duratorq - Td4, Removal and Installation).
Checking the radiator for leaks - with removal from the car
CAUTION: Do not leak test an aluminum radiator in the same water used to test copper/brass radiators. The water used for testing may contain flux and alkaline cleaners that will corrode the aluminum. If a separate container is not available, drain the test container and rinse it before testing the aluminum radiator.
Before starting the test, clean the radiator to avoid contaminating the test container. Check the radiator for leaks in clean water at an air pressure of 138 kPa.
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