Cooling System Leak Testing - Suzuki XL7 2007 Service Manual

4. Test the pressure cap for the following conditions:
– Pressure release when the J 24460-01 exceeds
the pressure rating of the pressure cap.
– Maintain the rated pressure for at least 10
seconds.
Note the rate of pressure loss.
5. Replace the pressure cap under the following
conditions:
– The pressure cap does not release pressure
which exceeds the rated pressure of the cap.
– The pressure cap does not hold the rated
pressure.

Cooling System Leak Testing

Special tool
J 24460-01 Cooling System Pressure Tester
J 42401 Radiator Cap/Surge Tank Test Adapter
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.
Engine Cooling System:
4. Use the J 24460-01 with J 42401 in order to apply
pressure to the cooling system.
– Wet the O-rings on the Surge Tank Pressure Test
Adapter J 42401-2 (insert) with water or clean
coolant and insert into tank.
– Wet the rubber gasket of the cap adapter J 42401-
3 (cap) and install on surge tank.
NOTE
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.
1F-20