0385756 JOHNSON COVER ASSEMBLY

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Cooling system pressure at specific altitudes and boiling points of water
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.
The coolant level must be to the correct level in order to check the coolant system. The engine must be cold and the engine must not be running. After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling system. Then remove the pressure cap.If the cooling system is equipped with a sight glass, the coolant should be to the correct level in the sight glass. On cooling systems without an indicator of the coolant level, fill the cooling system in order to be no more than 13 mm (0.5 inch) from the bottom of the filler pipe.Making the Correct Antifreeze Mixtures
Do not add pure antifreeze to the cooling system in order to adjust the concentration of antifreeze. Refer to Operation and Maintenance Manual, "Refill Capacities" for the correct procedure. The pure antifreeze increases the concentration of antifreeze in the cooling system. The increased concentration increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. The antifreeze mixture must consist of equal quantities of antifreeze and clean soft water. The corrosion inhibitor in the antifreeze will be diluted if a concentration of less than 50% of antifreeze is used. Concentrations of more than 50% of antifreeze may have the adverse effect on the performance of the coolant.Checking the Filler Cap
One cause for a pressure loss in the cooling system can be a faulty seal on the radiator pressure cap.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.
To check for the amount of pressure that opens the filler cap, use the following procedure:
After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the cooling system. Then, remove the filler cap.
Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface. Inspect the following components for any foreign substances:
Filler cap
Seal
Surface for sealRemove any deposits that are found on these items, and remove any material that is found on these items.
Install the pressure cap onto a suitable pressurizing pump.
Observe the exact pressure that opens the filler cap.
Compare the pressure to the pressure rating that is found on the top of the filler cap. The pressure cap should open within 95 to 110 kPa (13.7788 to 15.9544 psi). The pressure cap has a nominal pressure rating of 100 kPa (14.504 psi).
If the filler cap is damaged, replace the filler cap. Testing The Radiator And Cooling System For Leaks
Use the following procedure to test the radiator and the cooling system for leaks.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.
When the engine has cooled, loosen the filler cap to the first stop. Allow the pressure to release from the cooling system. Then remove the filler cap.
Make sure that the coolant covers the top of the radiator core.
Put a suitable pressurizing Pump onto the radiator.
Use the pressurizing pump to increase the pressure to an amount of 20 kPa (3 psi) more than the operating pressure of the filler cap.
Check the radiator for leakage on the outside.
Check all connections and hoses of the cooling system for leaks. The radiator and the cooling system do not have leakage if all of the following conditions exist:
You do NOT observe any leakage after 5 minutes.
The dial indicator remains constant beyond 5 minutes.The inside of the cooling system has leakage only if the following conditions exist:
The reading on the gauge goes down.
You do NOT observe any outside leakage.Make any repairs, as required.