WATER-COOLED CHARGE AIR COOLER COOLANT LEAKAGE
Warning:
– A hot engine can cause severe burns. Turn off the engine and wait until it is cool before removing the exhaust system.
– If the cooling system cap is removed when the engine is hot, steam and boiling water may be ejected, causing severe burns or severe injury. Perform the removal of the cooling system cap when the engine is cool.
– When removing the cooling system cap, cover the cooling system cap with a rag and remove it slowly.
Steps:
1. Open the engine cover.
2. Remove the water-cooled charge air cooler reserve tank cap.

4. Apply pressure using the radiator cap tester.
Caution:
– Applying more than 36 kPa {0.37 kgf/cm², 5.2 psi} can damage the hoses, fittings, and other components, and cause leakage.
– Engine coolant leakage inspection pressure: 36kPa (1 min).
5. When pressurizing the radiator, verify that the pressure is maintained.
– If the pressure decreases, repair or replace the location where water is leaking because water leakage can be considered.

COOLING SYSTEM CAP INSPECTION
Warning:
1. If the cooling system cap or the water-cooled charge air cooler reserve tank cap is removed when the engine is hot, steam and boiling water may be injected, causing severe burns or severe injury. Perform the removal of the cooling system cap and water-cooled charge air cooler reserve tank cap when the engine is cool.
2. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes.
3.  When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it.
Steps:
1.  Clean the vacuum valve and the seal area of the cooling system cap.
2. Verify that there is no damage or peeling on the seal area of the cooling system cap.
– If there is any malfunction, replace the cooling system cap.

4. Hold the cooling system cap downward, apply pressure gradually, and then verify that the tester pressure is maintained constant for approx. 10 s.
If the pressure is not maintained constant, replace the cooling system cap.
Cooling system cap opening valve pressure: 93.2-122.6 kPa.