Cooling System Inspection Checklist

This comprehensive cooling system inspection checklist ensures complete evaluation of engine cooling components to prevent overheating and costly engine damage. Covers coolant condition analysis, pressure testing, thermostat performance, water pump integrity, and radiator condition per OEM service intervals and ASTM D3306/D6210 coolant standards. Perform this inspection annually, at 30,000-mile intervals, or when overheating concerns arise.

Industry: Automotive Service
Frequency: Annually / Every 30,000 miles
Estimated Time: 30-45 minutes
Role: Service Technician / Master Technician
Total Items: 29
Compliance: ASTM D3306 / D6210 Coolant Standards, OEM Cooling System Service Intervals, EPA Antifreeze/Coolant Disposal Requirements, SAE J1004 Cooling System Standards, OSHA 29 CFR 1910.147 (LOTO for cooling service)

Coolant Condition & Protection Analysis

Test coolant chemistry, freeze protection, and contamination level. Degraded coolant becomes acidic and causes internal corrosion.

Freeze protection tested with refractometer - adequate for climate?
Coolant pH tested and in acceptable range (7.5-11)?
Coolant color appropriate for type - not brown, rusty, or oily?
Coolant within service interval (typically 5 years/150,000 miles for OAT)?
No signs of oil, combustion gases, or transmission fluid contamination in coolant?
Antifreeze/water mix ratio correct (typically 50/50)?
Coolant inhibitor/additive package still active (test strips or SCA check)?

System Pressure Test & Cap Test

Pressure test the cooling system to identify external and internal leaks. Also test radiator cap holding pressure.

Cooling system pressure tested to OEM spec (typically 15-18 PSI) - holds without dropping?
Radiator cap tested and holds rated pressure (number on cap)?
No external leaks found at hoses, clamps, heater core connections, or weep holes?
No coolant odor in cabin or fogging indicating heater core leak?
No signs of internal leaks (head gasket) - combustion gas test negative?

Cooling Components Condition

Physical inspection of all cooling system components for wear and damage.

Radiator fins clean and not bent excessively (over 20% blockage)?
Upper and lower radiator hoses firm, no soft spots, cracking, or swelling?
Water pump shows no bearing noise, wobble, or weep hole seepage?
Thermostat operation verified (engine reaches normal operating temp, heat works)?
Coolant overflow/recovery reservoir clean and undamaged?
Cooling fan(s) functional - electric fan activates with A/C or at operating temp?

Heater Core & Defroster Operation',

Verify heater core performance and defroster functionality, which depend on proper coolant flow.

Heater blows hot air at operating temperature (above 140°F output)?
Front defrost (fan/heater) clears windshield effectively?
Rear window defroster grid functional and clears within 5 minutes?
No sweet antifreeze smell in cabin indicating heater core leak?

Cooling System Service & Recommendation',

Document cooling system findings and service recommendations.

Coolant flush/exchange recommended based on condition or age?
Next coolant service interval noted on repair order?
Any hose replacements recommended documented with priority?
Old coolant disposed of per EPA antifreeze recycling requirements?
Customer informed of all cooling system findings and recommendations?
Customer queried about any overheating episodes that may indicate head gasket damage?
Cooling system air purged and no air pockets after service (if fluid was replaced)?

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Why Use This Cooling System Inspection Checklist?

This cooling system inspection checklist helps automotive service teams maintain compliance and operational excellence. Designed for service technician / master technician professionals, this checklist covers 29 critical inspection points across 5 sections. Recommended frequency: annually / every 30,000 miles.

Ensures compliance with ASTM D3306 / D6210 Coolant Standards, OEM Cooling System Service Intervals, EPA Antifreeze/Coolant Disposal Requirements, SAE J1004 Cooling System Standards, OSHA 29 CFR 1910.147 (LOTO for cooling service), UK BS EN 14774 Cooling Standards, India IS 6586 Coolant Standards. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Cooling System Inspection Checklist cover?

This checklist covers 29 inspection items across 5 sections: Coolant Condition & Protection Analysis, System Pressure Test & Cap Test, Cooling Components Condition, Heater Core & Defroster Operation',, Cooling System Service & Recommendation',. It is designed for automotive service operations and compliance.

How often should this checklist be completed?

This checklist should be completed annually / every 30,000 miles. Each completion takes approximately 30-45 minutes.

Who should use this Cooling System Inspection Checklist?

This checklist is designed for Service Technician / Master Technician professionals in the automotive service industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.