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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
Page2
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
Page3
Bayonet Filler Neck Configuration 1B
Cars and light trucks: Typicallyusedwithmostdomesticand Asianvehicleswitha16mmdeepneckandsmallstylebayonet.
Large over-the-road trucks:N/A
Toavoidinjury,makesureto use the correct retainer and that it securely fits the filler neck.
1 Adapter1/Black2 Retainer B3 Knurledring4 Smallrubberwasher5 Smallspacer6 Smallrubberwasher
1
2
3
4
5
6
Page4
Bayonet Filler Neck Configuration 1Cfor cars and light trucks
Cars and light trucks: Typicallyusedwithmostdomesticand Asianvehicleswitha9.5mmdeepneckandsmallstylebayonet.
Large over-the-road trucks:N/A
1 Adapter1/Black2 RetainerC3 Knurledring4 Smallrubberwasher
Toavoidinjury,makesureto use the correct retainer and that it securely fits the filler neck.
1
2
3
4
Page5
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.
Large over-the-road trucks:N/A
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.
Large over-the-road trucks:N/A
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.
Large over-the-road trucks:N/A
Inside Diameter
32 mm
9.5 mm
Cap gasket contactpoint with radiator neck
Adapter(1/black)
Page6
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.
Large over-the-road trucks:N/A
Outside Diameter
52 mm
3 mm
Cap gasket contactpoint with coolant
bottle neck.
Adapter(3/green)
Configuration 3aCars and light trucks: TypicallyusedwithFordFocusandEscape,JaguarXK8andXJ8,andMazdaTribute.
Large over-the-road trucks:N/A
Outside Diameter
52 mm
3 mmO-ring seals insidecoolant bottle neck.
Adapter(3/green)
Spindle A
Page7
External Threaded Filler Necks
Configuration 4Cars and light trucks: TypicallyusedwithJeep,Renault,Saab900,Sterling,andVolvo.
Large over-the-road trucks:N/A
Outside Diameter
45 mm
3 mm
Cap gasket contactpoint with coolant
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.
Large over-the-road trucks:N/A
Outside Diameter
48 mm
3 mm
Cap gasket contactpoint with coolant
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).
Large over-the-road trucks:N/A
Outside Diameter
52 mm
4 mm
Cap gasket contactpoint with coolant
bottle neck.Adapter(7/blue)
Configuration 9Cars and light trucks: Typically used withMercedes-Benz(exceptM-class1998to2005)andChryslerCrossfire(2004to2008).
Large over-the-road trucks:N/A
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.
Large over-the-road trucks:N/A
Outside Diameter
50 mm
2.5 mm
Cap o-ringseals with coolant
bottle neck.
Adapter(11/gray)
Page8
External Threaded Filler Necks
Configuration 12Cars and light trucks: N/A
Large over-the-road trucks:TypicallyusedwithVolvolargetrucks48mmx 3mm.
Outside Diameter
48 mm
3 mm Adapter(12/black)
Configuration 13Cars and light trucks: N/A
Large over-the-road trucks:TypicallyusedwithFreightliner60mmx3mm.
Outside Diameter
60 mm
3 mm
Cap gasket contactpoint with coolant
bottle neck.
Adapter(13/red)
Configuration 14Cars and light trucks: N/A
Large over-the-road trucks:TypicallyusedwithVolvotrucks63mmx3mm.
Outside Diameter
63 mm
3 mm
Cap gasket contactpoint with coolant
bottle neck.
Adapter(14/green)
Configuration 15Cars and light trucks: N/A
Large over-the-road trucks:TypicallyusedwithBsizetruckadapters.
Outside Diameter
2-3/16"
3/4"Cap gasket contactpoint with coolant
bottle neck Adapter(15/yellow)
Page9
Internal Threaded Filler Necks
Configuration 5bCars and light trucks: TypicallyusedwithAudiandVolkswagen(1998and later), some newer Bentley, Lamborghini,andPorschemodels.
Large over-the-road trucks:N/A
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).
Large over-the-road trucks:N/A
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.
Large over-the-road trucks:N/A
Outside Diameter
34 mm
3 mm
Cap O-Ring contactpoint with coolant
bottle neck.
Adapter(10/purple)
Page10
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)
Page11
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)
Thistestrequiresthefollowingcomponents:
• 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.
Page12
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)
Thistestrequiresthefollowingcomponents:
• 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.
Page13
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
Page14
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: support@hickok-inc.com
repaircenter@hickok-inc.com
Service address: Hickok Inc.Automotive Group1716 Carrollton Avenue Dock EGreenwood, MS 38930
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