Dodge Sprinter 2006 Manual page 833

VA
Fig. 2 PRESSURE TESTING
1 - PRESSURE RESERVOIR CAP
2 - PRESSURE RESERVOIR
3 - PRESSURE TESTER
Oper a t e t est er pu m p t o a pply 103.4 kP a (15 psi)
pr essu r e t o syst em . If h oses en la r ge excessively or
bu lges wh ile t est in g, r epla ce a s n ecessa r y. Obser ve
ga u ge poin t er a n d det er m in e con dit ion of coolin g sys-
t em a ccor din g t o followin g cr it er ia :
Ho ld s S te a d y : If poin t er r em a in s st ea dy for t wo
m in u t es, ser iou s coola n t lea ks a r e n ot pr esen t in sys-
t em . H owever, t h er e cou ld be a n in t er n a l lea k t h a t
does n ot a ppea r wit h n or m a l syst em t est pr essu r e. If
it is cer t a in t h a t coola n t is bein g lost a n d lea ks ca n -
n ot be det ect ed, in spect for in t er ior lea ka ge or per-
for m In t er n a l Lea ka ge Test .
D ro p s S lo w ly : In dica t es a sm a ll lea k or seepa ge
is occu r r in g. E xa m in e a ll con n ect ion s for seepa ge or
sligh t lea ka ge wit h a fla sh ligh t . In spect r a dia t or,
h oses, ga sket edges a n d h ea t er. Sea l sm a ll lea k h oles
wit h a Sea ler Lu br ica n t (or equ iva len t ). Repa ir lea k
h oles a n d in spect syst em
a pplied.
D ro p s Qu ic k ly : In dica t es t h a t ser iou s lea ka ge is
occu r r in g. E xa m in e syst em for ext er n a l lea ka ge. If
lea ks a r e n ot visible, in spect for in t er n a l lea ka ge.
La r ge r a dia t or lea k h oles sh ou ld be r epa ir ed by a
r epu t a ble r a dia t or r epa ir sh op.
INTERNAL LEAKAGE INSPECTION
Rem ove en gin e oil pa n dr a in plu g a n d dr a in a
sm a ll a m ou n t of en gin e oil. If coola n t is pr esen t in
t h e pa n , it will dr a in fir st beca u se it is h ea vier t h a n
oil. An a lt er n a t ive m et h od is t o oper a t e en gin e for a
sh or t per iod t o ch u r n t h e oil. Aft er t h is is don e,
r em ove en gin e dipst ick a n d in spect for wa t er glob-
a ga in wit h pr essu r e
u les. Also in spect t r a n sm ission dipst ick for wa t er
globu les a n d t r a n sm ission flu id cooler for lea ka ge.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Oper a t e en gin e wit h ou t pr essu r e ca p on coola n t
con t a in er u n t il t h er m ost a t open s. At t a ch a P r essu r e
Test er t o con t a in er. If pr essu r e bu ilds u p qu ickly it
in dica t es a com bu st ion lea k exist s. Th is is u su a lly
t h e r esu lt of a cylin der h ea d ga sket lea k or cr a ck in
en gin e. Repa ir a s n ecessa r y.
If t h er e is n ot a n im m edia t e pr essu r e in cr ea se,
pu m p t h e P r essu r e Test er. Do t h is u n t il in dica t ed
pr essu r e is wit h in syst em r a n ge of 110 kP a (16 psi).
F lu ct u a t ion of ga u ge poin t er in dica t es com pr ession or
com bu st ion lea ka ge in t o coolin g syst em .
Beca u se t h e veh icle is equ ipped wit h a ca t a lyt ic
con ver t er, d o n o t r em ove spa r k plu g ca bles or sh or t
ou t cylin der s t o isola t e com pr ession lea k.
If t h e n eedle on dia l of pr essu r e t est er does n ot
flu ct u a t e, r a ce en gin e a few t im es t o ch eck for a n
a bn or m a l a m ou n t of coola n t or st ea m . Th is wou ld be
em it t in g fr om exh a u st pipe. Coola n t or st ea m fr om
exh a u st pipe m a y in dica t e a fa u lt y cylin der h ea d ga s-
ket , cr a cked en gin e cylin der block or cylin der h ea d.
A con ven ien t ch eck for exh a u st ga s lea ka ge in t o
coolin g syst em is pr ovided by a com m er cia lly a va il-
a ble Block Lea k Ch eck t ool. F ollow m a n u fa ct u r er s
in st r u ct ion s wh en u sin g t h is pr odu ct .
COMBUSTION LEAKAGE TEST - WITHOUT PRES-
SURE TESTER
DO NOT WASTE r eu sa ble coola n t . If solu t ion is
clea n , dr a in coola n t in t o a clea n a n d su it a bly m a r ked
con t a in er for r eu se.
WARNING: Do not remove cylinder block drain
plugs or loosen radiator drain with system hot and
under pressure. serious burns from coolant can
occur.
Dr a in su fficien t coola n t
r em ova l.
Rem ove a ccessor y dr ive belt .
Add coola n t t o pr essu r e con t a in er t o br in g level t o
wit h in 6.3 m m (1/4 in ) of t op of t h er m ost a t h ou sin g.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
ENGINE 7 - 11
t o a llow t h er m ost a t