2015 CST Cooling System Test Kits User Guide CST Cooling System Test Kits User Guide For use with...

2015 CST Cooling System Test Kits User Guide For use with all Hickok/Waekon CST Cooling System Test Kits

Select and Assemble the Cap Adapter

Before you can start the testing procedures, you need to select, assemble and connect the appropriate adapter for the vehicle you are testing. Warning! To avoid injury or damage, never remove a vehicle’s radiator cap or tester while the cooling system is under pressure.

1. Remove the cap from the vehicle’s filler neck and determine the style used (bayonet, external thread, internal thread).

2. Using the chart on the following pages, locate the cap adapter configuration that best matches the vehicle’s filler neck. When selecting, keep the following in mind:

• Toavoidcrossthreadingandre-threading,never force an adapter onto a filler neck. If the adapter does not thread on smoothly, select another adapter.

• Typicallyifthevehicle’scaphasaspindle,youwillalsoneedtouseonewiththeadapterfor proper sealing.

• Forconfigurations1A,1B,and1C(carsandlighttrucks)alwaysmakesuretousethecorrectretainerandthatitsecurelyfitsthefillerneck.Failuretodosomayresultininjury.

3.Assembletheadapter.

IMPORTANT! Please make sure to carefully read all instructions, including the safety information at the back of this sheet before you begin testing.

Kit Contents

Storage case

Large/Smallspacer

Large/Smallrubber washerPressure regulator

1 Universal Cam adapter

Spindle A Spindle BRetainer A,B,C

Knurled ring

1 Black

11 gray

3 green 4 yellow

9 red

7 blue 8 brown

8

2 white 5 black

10 purple

Relief hose

13 red 14 green 15 yellow12 Black

CST Cooling System Kits for Cars and Light Trucks:

62831 Cooling System Base Kit 62801 Cooling System Adapter Kit 62868 Cooling System Test & Adapter Kit•Adapter#1•RetainersA,B,&C•PressureRegulator•ReliefHose

•KnurledRing •Washers•Spacers•StorageCase

•Adapters#2to#11•SpindlesA&B•StorageCase•UniversalCamAdapter

•62831BaseKit•62801AdapterKit

CST Heavy Duty Cooling System Kits for Large Over-the-Road Trucks:

62901 HD Cooling System Adapter Kit 62968 HD Cooling System Test Kit•Adapters#2,#12,#13,#14,#15•UniversalCamAdapter•SpindleA•StorageCase

•PressureRegulator•Adapters#2,#12,#13,#14,#15•SpindleA

•ReliefHose•StorageCase

Bayonet

ExternalThread

InternalThread

Bayonet Filler Neck Configuration 1A

Cars and light trucks: Typicallyusedwithmostearlymodelvehicleswithlarge stylebayonet(StandardA).Mayalsobeusedonsomecurrentmodelvehicles.

Large over-the-road trucks:N/A

Toavoidinjury,makesureto use the correct retainer and that it securely fits the filler neck.

Shippedfromfactorypre-configured

1 Adapter1/Black2 RetainerA3 Knurledring4 Smallrubberwasher5 Smallspacer6 Smallrubberwasher7 Large spacer8 Largerubberwasher

1

2

3

4

5

6

7

8

Bayonet Filler Neck Configuration 1B

Cars and light trucks: Typicallyusedwithmostdomesticand Asianvehicleswitha16mmdeepneckandsmallstylebayonet.



1 Adapter1/Black2 Retainer B3 Knurledring4 Smallrubberwasher5 Smallspacer6 Smallrubberwasher

1

2

3

4

5

6

Bayonet Filler Neck Configuration 1Cfor cars and light trucks

Cars and light trucks: Typicallyusedwithmostdomesticand Asianvehicleswitha9.5mmdeepneckandsmallstylebayonet.


1 Adapter1/Black2 RetainerC3 Knurledring4 Smallrubberwasher


1

2

3

4

Bayonet Style Filler NecksUse with Bayonet Configuration Shown

Configuration 1aCars and light trucks: Typicallyusedwith most early model vehicles and some newer ones with a large bayonet style neck.


Inside Diameter

1-5/8"

3/4"Cap gasket contact

point with radiator neck

Adapter(1/black)

Configuration 1bCars and light trucks: TypicallyusedwithDomesticandAsianvehicleswith a deep neck.


Inside Diameter

31 mm

16.0 mmCap gasket contact

point with radiator neck

Adapter(1/black)

Configuration 1cCars and light trucks: TypicallyusedwithDomesticandAsianvehicleswith a shallow neck.


Inside Diameter

32 mm

9.5 mm

Cap gasket contactpoint with radiator neck

Adapter(1/black)

External Threaded Filler Necks

Configuration 2Cars and light trucks:Typicallyusedwithmany1990tocurrentdomesticvehicles(especiallyGM)andsomeMercedes,Jaguar,andFord.

Large over-the-road trucks: TypicallyusedwithFreightliner,GM,International,Kenworth,andPeterbuilt.

Outside Diameter

52 mm

2.5 mm

Cap gasket contactpoint with coolant

bottle neck.

Adapter(2/white)

Configuration 2aCars and light trucks: Typicallyusedwithmany1999tocurrentdomesticvehicles(especiallyGM)andsomeMercedes,Jaguar,andFord.

Large over-the-road trucks:TypicallyusedwithFord,Freightliner,GM,andNavistar.

Outside Diameter

52 mm

2.5 mm

O-ring seals insidecoolant bottle neck.

Adapter(2/white)

Spindle A

Configuration 3Cars and light trucks: TypicallyusedwithPorsche,Mercury,Saturn,Saab,Jaguar,RangeRover,Pontiac,Daewoo,andFord.


Outside Diameter

52 mm

3 mm


bottle neck.

Adapter(3/green)

Configuration 3aCars and light trucks: TypicallyusedwithFordFocusandEscape,JaguarXK8andXJ8,andMazdaTribute.


Outside Diameter

52 mm

3 mmO-ring seals insidecoolant bottle neck.

Adapter(3/green)

Spindle A


Configuration 4Cars and light trucks: TypicallyusedwithJeep,Renault,Saab900,Sterling,andVolvo.


Outside Diameter

45 mm

3 mm


bottle neck.

Adapter(4/yellow)

Configuration 5Cars and light trucks: Typicallyusedwith most early model vehicles and some newer ones with a large bayonet style neck.


Outside Diameter

48 mm

3 mm


bottle neck.

Adapter(5/black)

Adapter also hasinternal threadswhich are not shown in this view.

Configuration 7Cars and light trucks: TypicallyusedwithBMW(1988to2006withexternal thread on coolant bottle), andRangeRover(1995to1997).


Outside Diameter

52 mm

4 mm


bottle neck.Adapter(7/blue)

Configuration 9Cars and light trucks: Typically used withMercedes-Benz(exceptM-class1998to2005)andChryslerCrossfire(2004to2008).


Outside Diameter

62 mm

4 mm

Cap o-ringseals with coolant

bottle neck.

Adapter(9/red)

Configuration 11Cars and light trucks: TypicallyusedwithnewerFordmodels(Escape,Fiesta,Focus,Fusion),LandRoverLr2,Mazda3&6,NewerVolvomodels.


Outside Diameter

50 mm

2.5 mm

Cap o-ringseals with coolant

bottle neck.

Adapter(11/gray)


Configuration 12Cars and light trucks: N/A

Large over-the-road trucks:TypicallyusedwithVolvolargetrucks48mmx 3mm.

Outside Diameter

48 mm

3 mm Adapter(12/black)


Large over-the-road trucks:TypicallyusedwithFreightliner60mmx3mm.

Outside Diameter

60 mm

3 mm


bottle neck.

Adapter(13/red)


Large over-the-road trucks:TypicallyusedwithVolvotrucks63mmx3mm.

Outside Diameter

63 mm

3 mm


bottle neck.

Adapter(14/green)


Large over-the-road trucks:TypicallyusedwithBsizetruckadapters.

Outside Diameter

2-3/16"

3/4"Cap gasket contactpoint with coolant

bottle neck Adapter(15/yellow)

Internal Threaded Filler Necks

Configuration 5bCars and light trucks: TypicallyusedwithAudiandVolkswagen(1998and later), some newer Bentley, Lamborghini,andPorschemodels.


Outside Diameter

63 mm

3 mmCap O-Ring contactpoint with coolant

bottle neck.

Adapter(5/black)

Spindle B

Configuration 8Cars and light trucks: TypicallyusedwithVolkswagen(1990to1998).


Outside Diameter

56.5 mm

3 mm

Cap O-Ring contactpoint with coolant

bottle neck.

Adapter(8/brown)

Configuration 10Cars and light trucks: TypicallyusedwithnewerLexus,ToyotaSpyderandCelica,andScion.


Outside Diameter

34 mm

3 mm

Cap O-Ring contactpoint with coolant

bottle neck.

Adapter(10/purple)

Optional Universal Adapter

ThisadapterallowsyoutousetypicalCAMstylehandpumpswiththeCSTCoolingadapters.

Theadapterisavailablewiththe62801CoolingsystemAdapterKit,andthe62901HDCoolingSystemAdapterKit.You may also purchase the adapter separately.

Before You BeginYou must attach a shop air quick disconnect fitting to the pressure regulator.

For the best test results

• Performthetestsintheorderlisted

• Whenusingshopair,90–125psiisrecommended

Step 1—Visually Inspect for Leaks / Damage

• Hoses,clampsandbelts • Sufficientairflow • Thermostathousing

• Radiator • Waterpump • Heatercore

• Coolantlevelandcondition • Watercontrolvalve • Cylinderhead/intakemanifold

If any of these conditions exist, repair or replace components as necessary before continuing.

Step 2—Check for Service CodesChecktheenginecontrolmoduleforanyservicecodes.Thesecodesmayverifyacoolingsystemrelatedsymptomandshouldbe serviced before testing.

Test Procedures

Adapter1

Filler Neck

Filler Neck

2

Adapter 1/Black1

Retainer A, B or C2

3

Step 3—Select and Assemble Cap AdapterUsing the reference chart, locate and assemble the appropriate cap adapter configuration for the vehicle.

Step 4—Connect to the Vehicle1. With the system cooled and the engine off, carefully remove the

pressure cap from the radiator or service tank.

2. Securelyattachthecapadapterassemblytotheradiatororfillerneck the same as you would the pressure cap.

3. Connectthepressureregulatortothecapadapterassemblyper the instructions for the particular test procedure you are performing.

To Disconnect From the Vehicle

1.VerifythattheballvalveisintheOFF position and then remove the shop air from the pressure regulator.

2.Connectoneendofthepressurerelief hose to the regulator airline adapter and the other end of the hose into a container (tocapturehotcoolant).TurntheballvalvetotheON position to relieve the system pressure from the previous test.

3. Once the pressure is relieved, remove the pressure relief hose and turn the ball valve to the OFF position.

4. Removeadapter(s)

Step 5—Pressure/Leak Test (Cold Engine)

Thistestrequiresthefollowingcomponents:

• Configuredcapadapterforthevehicleyouaretesting• PressureRegulator

Procedure:

Perform this test with the engine off.

1. Remove the vehicle’s radiator cap and connect the adapter assembly to the filler neck.

2.Connectthepressureregulatortothecapadapter.MakesuretheballvalveisintheOFF position

3.Connecttheshop’sairsupplytothePressureRegulatorviathequickdisconnect.

4. TurntheballvalvetotheON position (handle is parallel to the air hose).

5. Slowlyturnthecontroldialontheregulatoruntilthepressuregaugeisatthevehicle’sratedpressure.

Tip: Once the desired pressure is reached, you can lock the dial by pressing in the collar on the dial. Unlock the dial by pulling the collar out.

6. Inspectthecoolingsystemforanyexternalleaks.Thisincludesthefollowingareas:

• Hoses,Radiator,Watercontrolvalve • Heatercore

• Thermostathousing • Cylinderhead/intakemanifold

• Waterpump • Coolantrecovery/reservetank

Note: If any leaks are found, repair and retest before proceeding to the next step.

7. TurntheballvalvetotheOFF position and observe the pressure gauge readings.

• Ifthesystemmaintainsthepressure,proceedtothenexttest,Pressure Test—Warming Engine.

• Ifthesystemdoesnotholdthepressure,andthegaugereadingsbegintodrop,aleakispresent.

Checkforanyindicationofanexternalleak.Ifnoleakisfound,suspectaninternalleak(checkforcoolantintheoil).

Repair and retest before proceeding to the next step.

Step 6—Pressure Test (Warming Engine)


• Configuredcapadapterforthevehicleyouaretesting• Pressurereliefhose• Pressureregulator

Start this test with the engine off and cold coolant.

1.VerifythattheballvalveisintheOFF position and then remove the shop air from the pressure regulator.

2.Connectoneendofthepressurerelief hose to the regulator airline adapter and the other end of the hose into a container(tocapturehotcoolant).TurntheballvalvetotheON position to relieve the system pressure from the previous test.

3. Once the pressure is relieved, remove the pressure relief hose and turn the ball valve to the OFF position.

4. Turnthepressurecontroldialclockwiseuntilitstops.

5. Startthevehicle’sengineandallowtoidle.

6.Observethepressuregaugeastheenginewarmsup.

WarningTo avoid serious injury or damage while performing any of these tests, make sure you do the following:

• Donotpressurizethesystem(orallowthepressuretoincrease) beyond the radiator cap release pressure.

• Turntheengineoffimmediatelyifitbeginstooverheat.

• AlwaysmakesuretheballvalveisintheOFFpositionwhenever connecting or disconnecting the shop airline to theregulator.Failuretodosomayresultinreleasinghot/pressurizedcoolant.

If the system is operating normally:• Thepressuregaugeincreasegraduallyastheenginewarmsup.

If the system is NOT operating normally:• Thepressurerisesrapidly.Thisisusuallycausedbycylindercompressionleakingintothecoolingsystemfroma

cracked cylinder head or gasket leak.

• Thepressurefluctuates.Thisisusuallycausedbyacrackbetweenthevalveseatsandheadgasket.

If the system is operating normally, proceed to the next step. Otherwise make any necessary repairs and retest before proceeding.

Donotperformthisnextstepifthevehicle’sthermostatislocatedinthelowerhose.

7. Asthepressurerises,increasetheengineRPMtoapproximately2000whileobservingthepressuregauge.

If the system is operating normally:• ThepressurewilldropslightlyastheRPMsincrease.

If the system is NOT operating normally:• Ifthepressuredrops,suspectlowcoolantflowfromthewaterpump.

• Ifthepressureincreases,suspectapluggedradiator.

If the system is operating normally, proceed to the next test, Pressure/leak Test—Hot Engine. Otherwise make any necessary repairs and retest before proceeding.

Step 7—Pressure/Leak Test (Hot Engine)


• Configuredcapadapterforthevehicleyouaretesting• Pressurereliefhose• Pressureregulator

Procedure:

Perform this test with the engine off but with the coolant and engine hot.

USE EXTREME CAUTION—coolant is hot and can cause serious injury.

1.Connecttheshop’sairsupplytothepressureregulatorviathequickdisconnect.

2. TurntheballvalvetotheON position (handle is parallel to the air hose).

4. Slowlyturnthecontroldialontheregulatoruntilthepressuregaugeisatthevehicle’sratedpressure.

5. Inspectthecoolingsystemforanyexternalleaks.Thisincludesthefollowingareas:

• Hoses • Waterpump

• Radiator • Heatercore

• Watercontrolvalve • Cylinderhead/intakemanifold

• Thermostathousing • Coolantrecovery/reservetank

Note: If any leaks are found, repair and retest before proceeding to the next step.

6. TurntheballvalvetotheOFF position and observe the pressure gauge readings.

• Ifthesystemmaintainsthepressure,aleakisnotpresent.The test is complete.

• Ifthesystemdoesnotholdthepressure,andthegaugereadingsbegintodrop,aleakispresent.

Checkforanyindicationofanexternalleak.Ifnoleakisfound,suspectaninternalleak(checkforcoolantintheoil).Repair and retest.

Safety Information

Before using this equipment, carefully read, understand and follow instructions and safety messages on equipment and in this guide.

Theguidecannotanticipateorprovideadviceandcautionsfor all situations encountered by technicians. With this in mind, always follow and refer to the manuals provided by the manufacturer or the vehicle or equipment being tested or used for all information and testing procedures whenever diagnosing, repairing or operating such vehicle or equipment.

Failuretofollowtheinstructions,cautionsandwarningsprovided here as well as those provided by the vehicle and equipment manufacturers can result in fire, explosion, bodily injuryandpropertydamage.

Vehicles emit flammable vapors which can ignite.

• Keepflames,sparks,cigarettesandotherignitionsourcesaway from the vehicle at all times.

• Incaseoffire,neverusewatertofightflamescausedbymethanolormethanolblendedgasoline.Thiswillcausetheflames to spread instead of extinguishing them.

• Useadrychemicalextinguishertofightflames(preferablyonemarkedABC,thoughBCisacceptable).AfoamextinguisherisacceptableonlyifitisARFgrade,whichisresistant to alcohol.

To avoid serious injury, do the following:• Usecautionwhentestingonavehiclewhiletheengineis

running (electric cooling fans may turn on unexpectedly eveniftheignitionisintheOFFposition,surfacesmaybecome hot, etc.)

• Removerings,watches,looseorhangingjewelry.Tielonghairsecurelybehindthehead.Takeextracarewithlooseorhanging clothing.

• Alwayswearapprovedsafetyglasseswhentesting.Shouldcoolant get into eyes, flush eyes immediately with water and consult your physician.

• Iftheskinisdirectlyexposed,washtheareaimmediatelyand change any clothes that have become wet with coolant.

• Neverremoveavehicle’sradiatorcaportesterwhilethecooling system is under pressure.

Before beginning any tests, make sure the test environment is safe and the vehicle meets these testing conditions:

• Testareashouldbewellventilated.

• Vehicleshouldbeinpark.

• Wheelsshouldbeblocked.

• Vehicleshouldhavenormalexhaustflow.

• Keepalltestercablesclearofexhaustmanifoldsandradiatorfan blades.

Warranty

Subjecttotheconditionsthatfollowandarenotedbelow,thisproductiswarrantedtobefreefromdefectsinmaterialandworkmanship,underproperuse and in accordance with the manufacturer’s written recommendation and specifications, for a period designated below on all products:

• Thisproductcarriesalimitedlifetimewarrantyontheadaptersandaoneyearwarrantyofthepressureregulator.

Themanufacturer’sobligationunderthiswarrantyislimitedtounalteredproductsreturnedtothemanufacturerbytheinitialenduserofthenewproducts.Therefore,thiswarrantydoesnotcoveranyproductsresoldbytheendusertothirdparties,noranyreconditionedproductssoldassuch,bythemanufacturer.Thesoleremedyforanysuchdefectshallbetherepair,orreplacement,oftheproductatthesolediscretionofthemanufacturer.Thiswarranty does not cover expendable parts, such as batteries, nor does it cover shipping or handling. In addition, manufacturer is not liable for any loss or damage to product during shipping.

In the event it is determined that the product has been tampered with, or altered in any way, this warranty is void and all claims against the product will notbehonored.Allwarrantyclaimsmustbesubmittedasoutlinedbythemanufacturerandshallbeprocessedinaccordancewiththemanufacturer’sestablishedwarrantyclaimprocedures.Theseproceduresincludeprovisionsthatproofofpurchasemustbeestablished(byeitherwarrantycardfromtheseller or by point of purchase receipt) and that the manufacturer will make every attempt to return ship the product within one business day from receipt of the returned product, freight prepaid.

Inaddition,allmaintenanceprocedures,asoutlinedbytheproductmanuals,shouldbefollowedforthewarrantytobekeptinforce.Shouldtheproductnot be used in accordance with procedures as specified, or if the product otherwise fails outside of the warranty, the manufacturer reserves the right to makesuchjudgmentandthepartyreturningtheproductwillbenotifiedthatwrittennotificationwillbenecessarytorepairtheproductatacostwhichthemanufacturerdeemsasreasonable.Theproductwillthenbeshippedbacktothecustomer,COD;orasthemanufacturerdeemsappropriate.

Thisistheonlyauthorizedmanufacturer’swarrantyandisinlieuofallotherexpressed,orimplied,warrantiesorrepresentations,includingbutnotlimited to any implied warranties of merchantability or fitness or any other obligations on the part of the manufacturer. In no event will the manufacturer beliableforbusinessinterruptions,lossofprofit,personalinjury,costsofdelays,oranyspecial,indirect,incidentalorconsequentialdamages,costsorlosses.

Safety Information & Warranty

Contact Information

If you have any questions about our products including technical assistance, call our customer care department during standardbusinesshoursEST.Ifacustomercarerepresentativedirectsyoutoreturnanyequipment,besuretoincludethese items:

• awrittendescriptionoftheproblem;

• thenameandtelephonenumberofyourcontactperson;

• yourshippingaddress,and

• ourreturnauthorizationnumber(fromcustomercare).

Customer care and tech support: 800/342-5080

Service and repair center: 662/453-6212

Fax: 216/761-9879

E-mail: [email protected]

[email protected]

Service address: Hickok Inc.Automotive Group1716 Carrollton Avenue Dock EGreenwood, MS 38930

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2015 CST Cooling System Test Kits User Guide CST Cooling System Test Kits User Guide For use with...

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