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 in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

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

Caution: Refer to General Repair Instructions in the Preface section.

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).

Notice: Refer to General Repair Instructions in the Preface section.

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

Notice: Refer to General Repair Instructions in the Preface section.




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 in the Preface section.

4. Install the coolant pressure cap.

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