Radiator Cap: Testing and Inspection

Pressure Cap Testing

Tools Required

* J 24460-01 EN-48501 Pressure Cap Adapter
* J 24460-01 J-48501 Radiator Cap Pressure Adapter
* J 24460-01 J-24460-01 Cooling System and Cap Pressure Tester



Caution: 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.


Caution: 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.

Caution: Refer to Radiator Cap Removal Caution (Service Precautions) .
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .

Ensure engine is below 50 C before removing the coolant pressure cap.




Non Registered Caution: Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 120919 in Cautions and Notices.
Caution: Only use water to wet the cloth

Inspect and clean the sealing O-rings (1) with a wet cloth.





1. Attach the coolant filler cap (1) to a commercially available cooling system pressure tester (2), using the pressure cap adapter (4) and the pressure tester adapter (3).

Non Registered Notice: Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 120919


Notice: Should the coolant pressure cap fail to reach or hold the specified pressure, replace the cap.

2. Slowly pressurise cap to 120 - 150 kPa (17 - 22 psi).





Non Registered Notice: Refer to PSD SIE TITLE Error: SIE linked to empty Cell ID 120919


Notice: The V6 coolant filler neck is shown in the illustration above, for the V8 variant the coolant filler neck is located on the radiator assembly.

3. Prior to installing the coolant pressure cap ensure that the coolant filler neck cap seating surface (1) is clean and free from obstruction.

Notice: Refer to Fastener Notice (Fastener Notice) .

4. Install the coolant pressure cap.

Tighten the cap to 3.0 Nm (27 lb in).