For 1990-2009 cars

#### Tools Required

• | KM-6327 Pressure Tester Adapter (previously released for Vectra)

• | KM-471 Pressure Tester Adapter (previously released for Vectra)

• | 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.

Remove the coolant pressure cap.

Test the operation of the coolant pressure cap. Refer to Pressure Cap Testing .

Ensure that the coolant level is correct.

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

1. Install the coolant filler neck adapter (2) to commercially available cooling system pressure tester (1).
2. Install the assembly to the engine coolant filler neck.
3. Using compressed air, blow dry any spilled coolant around coolant filler neck.

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

4. Using the cooling system pressure tester pump, pressurise the cooling system to 150 kPa (22 psi) absolute maximum and check for leaks at the following points:

• | All hose and hose connections.

• | Overflow hose connection at coolant outlet housing connection.

• | Radiator seams and core.

• | Corroded or damaged engine core plugs.

• | Water pump and gasket.

• | Thermostat housing and inlet pipe connection.

• | Radiator drain cock.

• | Vehicle heating system (e.g. heater core and water valve).

• | Check engine oil dipstick for evidence of engine oil contamination with the coolant.

5. Repair any leaks as required.

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

6. If pressure will not hold, there is a leak in the cooling system. Repair as necessary.

#### Black Light and Dye Leak Diagnosis Method

Caution: Refer to Cooling System Draining and Filling in the Preface section.

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.

1. Remove the pressure cap.
2. Pour a specified amount of dye into the cooling system.
3. Road test the vehicle under normal operating conditions.
4. Direct the black light towards the suspect area. Any fluid leak will appear as a bright coloured path leading to the source.
5. Repair the fluid leak and carry out a second road test to ensure the leak has been rectified.
6. Refer to the manufacture's direction when preforming this method.