ON-VEHICLE INSPECTION Of RADIATOR & CONDENSER MODULE

WARNING: This page is about a different car, the 2002 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure.

Remove radiator cap.

NOTE:

If the radiator cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps ( a) and ( b), keep the radiator cap tester at an angle of over 30° above the horizontal.

Inspect radiator cap:
1. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve.
  
  Fig 1: Using Radiator Cap Tester
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Pump speed: One push (3 seconds or more)
  
  NOTE: Push the pump at a constant speed.
  
  If air is not coming from the vacuum valve, replace the radiator cap.
2. Pump the tester and measure the relief valve opening pressure.
  Pump speed: one push within one second
  
  NOTE: This pump speed is for the first pump only (in order to close the vacuum value). After this, the pump speed can be reduced.
  
  Standard opening pressure: 74-103 kPa (0.75-1.05 kgf.cm ² , 10.7-14.9 psi)
  
  Minimum opening pressure: 79 kPa (0.8 kgf.cm ² , 11.5 psi)
  
  NOTE: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap.
Inspect cooling system for leaks:
1. Fill the radiator with coolant and attach a radiator cap tester.
  
  Fig 2: Pressure Testing Coolant System
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Warm up the engine.
3. Pump it to 118 kPa (1.2 kgf.cm² , 17.1 psi), and check that the pressure drops.
Reinstall radiator cap.