Test Description
The numbers below refer to the step numbers on the diagnostic table.
- 6: A test lamp that remains illuminated indicates a short to ground on the control circuit. A test lamp that does not illuminate indicates an open or short to voltage on the control circuit.
- 8: This step tests the control circuit for high resistance.
| Step | Action | Values | Yes | No |
|---|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics (Notchback) or Engine Cooling Schematics (Hatchback) Connector End View Reference: Cooling System Connector End Views (Notchback) or Cooling System Connector End Views (Hatchback) | ||||
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle | |
| 2 | Turn ON the ignition, with the engine OFF. With a scan tool, command the Fan Low Speed ON and OFF. Does the relay turn ON and OFF with each command? | Go to Step 3 | Go to Step 4 | |
| 3 | With a scan tool, command the Fan High Speed ON and OFF. Do the relay turn ON and OFF with each command? | Go to Diagnostic Aids | Go to Step 4 | |
| 4 | Turn OFF the ignition. Disconnect the affected relay. Turn ON the ignition, with the engine OFF. Probe the ignition 1 voltage circuit of the affected relay coil with a test lamp connected to a good ground. Does the test lamp illuminate? | Go to Step 5 | Go to Step 13 | |
| 5 | Turn ON the ignition, with the engine OFF. Probe the control circuit of the affected relay with a test lamp connected to battery positive. With a scan tool, command the affected relay ON and OFF. Does the test lamp turn ON and OFF? | Go to Step 7 | Go to Step 6 | |
| 6 | Does the test lamp remain illuminated? | Go to Step 9 | Go to Step 10 | |
| 7 | Turn OFF the ignition. Disconnect the MAIN relay in the underhood fuse block. Measure the resistance of the ignition 1 voltage circuit of the affected relay coil from the MAIN relay terminal to the affected relay terminal. Is the resistance less than the specified value? | 3 ohms | Go to Step 8 | Go to Step 13 |
| 8 | Turn ON the ignition, with the engine OFF. IMPORTANT: Use a test lamp that measures between 25-30 ohms for this test. Probe the control circuit of the affected relay with a test lamp connected to battery positive voltage. With a scan tool, command the affected relay ON. Measure the voltage from the probe of the test lamp to a good ground with a DMM. Is the voltage less than the specified value? | 2.5 V | Go to Step 11 | Go to Step 10 |
| 9 | Test the control circuit of the affected relay for a short to ground. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | Go to Step 16 | Go to Step 12 | |
| 10 | Test the control circuit of the affected relay for one of the following conditions: An open A short to voltage High resistance Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | Go to Step 16 | Go to Step 12 | |
| 11 | Test for shorted terminals and poor connections at the affected relay. Refer to Testing for Intermittent Conditions and Poor Connections . Did you find and correct the condition? | Go to Step 16 | Go to Step 14 | |
| 12 | Test for shorted terminals and poor connections at the engine control module (ECM). Refer to Testing for Intermittent Conditions and Poor Connections . Did you find and correct the condition? | Go to Step 16 | Go to Step 15 | |
| 13 | Repair the open, short to ground, or high resistance on the ignition 1 voltage circuit. Refer to Wiring Repairs . Did you complete the repair? | Go to Step 16 | ||
| 14 | Replace the affected relay. Refer to Relay Replacement (Within an Electrical Center) . Did you complete the replacement? | Go to Step 16 | ||
| 15 | Replace the ECM. Did you complete the replacement? | Go to Step 16 | ||
| 16 | Clear the DTCs with a scan tool. Turn OFF the ignition for 30 seconds. Start the engine. Operate the vehicle within the Conditions for Running the DTC. Did the DTC fail this ignition? | Go to Step 2 | Go to Step 17 | |
| 17 | Are there any DTCs that have not been diagnosed? | Go to Diagnostic Trouble Code (DTC) List - Vehicle | System OK | |
| IMPORTANT |
|---|
| Use a test lamp that measures between 25-30 ohms for this test. |
Symptoms - Engine Cooling
| IMPORTANT | The following steps must be completed before using the symptom tables. |
- Perform the «Diagnostic System Check - Vehicle»(ref-300843-S03018657462008101600000) before using the Symptom Tables in order to verify that all of the following are true: There are no DTCs set. The control module(s) can communicate via the serial data link.
- Review the system operation in order to familiarize yourself with the system functions. Refer to «Cooling System Description and Operation»(ref-300853-S25033250582008101600000) .
The numbers below refer to the step numbers on the diagnostic table.
- 4: This step, along with step 5, checks for the ability of the ECM to operate the cooling fans.
- 8: This step, along with step 9, checks for the ability of the ECM to operate the cooling fans in response to A/C pressure readings.
- 16: After confirming battery voltage and the ECM supplying a ground to the coil side of the cooling fan relay A, by jumpering connector terminals 30 and 87, it will be determined if the relay is at fault or a wiring problem is present.
- 31: This step checks for the presence of battery voltage to the main cooling fan when the A/C is ON. If battery voltage is present and the cooling fans are not operating, the problem is in the ground side of the cooling fan circuit.
- 37: By directly grounding the ECM low relay and high relay control circuits, the main and auxiliary cooling fans should run at high speed.
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle |
| 2 | Inspect the I/P engine block fuse EF3. Replace the fuse as needed. Is the fuse OK? | Go to Step 3 | Go to Diagnostic Aids |
| 3 | Inspect the I/P fuse block fuse F18. Replace the fuse as needed. Is the fuse OK? | Go to Step 4 | Go to Diagnostic Aids |
| 4 | Turn the ignition OFF. Turn the A/C switch OFF. Connect a scan tool to the data link connector (DLC). The cooling fans should run at low speed when the coolant temperature reaches 97°C (207°F). Do the cooling fans run at low speed? | Go to Step 5 | Go to Step 10 |
| 5 | Turn the ignition OFF. Turn the A/C switch OFF. Connect a scan tool to the DLC. Start the engine. The cooling fans should run at high speed when the coolant temperature reaches 101°C (214°F). Do the cooling fans run at high speed? | Go to Step 6 | Go to Step 33 |
| 6 | Turn the ignition OFF. Start the engine. Turn the A/C switch ON. Does the A/C compressor clutch engage? | Go to Step 8 | Go to Step 7 |
| 7 | Diagnose the A/C compressor clutch circuit. Repair the A/C compressor clutch circuit as needed. Start the engine. Turn the A/C switch ON. Does the A/C compressor clutch engage? | Go to Step 8 | |
| 8 | Do the cooling fans run at low speed? | Go to Step 9 | Go to Step 31 |
| 9 | Turn the ignition OFF. Connect the A/C pressure gages. Start the engine. Turn the A/C switch ON. The cooling fans should run at high speed when the high side A/C pressure reaches 1 882 kPa (273 psi). Do the cooling fans run at high speed? | Go to Step 10 | Go to DTC P0532 or P0533 |
| 10 | Turn the ignition OFF. Connect a scan tool to the DLC. The coolant temperature should be above 97°C (207°C). Disconnect the main cooling fan connector. Turn the ignition ON. Connect a test light between the main cooling fan connector terminal 2 and ground. Is the test light ON? | Go to Step 11 | Go to Step 12 |
| 11 | Turn the ignition OFF. Connect a scan tool to the DLC. The coolant temperature should be above 97°C (207°C). Disconnect the main cooling fan connector. Connect a test light between the main cooling fan connector terminal 1 and B+. Is the test light ON? | Go to Step 28 | Go to Step 17 |
| 12 | Turn the ignition OFF. Disconnect the cooling fan relay LOW. Connect a test light between the cooling fan relay LOW connector terminal 86 and ground. Turn the ignition ON. Is the test light ON? | Go to Step 13 | Go to Step 24 |
| 13 | Turn the ignition OFF. Connect the cooling fan relay LOW. Disconnect engine control module (ECM) white connector. Connect a fused jumper between the ECM low cooling fan relay control circuit and ground. Turn the ignition ON. Do the cooling fans run at low speed? | Go to Step 30 | Go to Step 14 |
| 14 | Inspect for an open wire between the low speed cooling fan relay connector terminal 86 and the ECM low cooling fan relay control circuit. Is the problem found? | Go to Step 25 | Go to Step 15 |
| 15 | Turn the ignition OFF. Disconnect the cooling fan relay LOW. Connect a test light between the cooling fan relay LOW connector terminal 30 and ground. Is the test light ON? | Go to Step 16 | Go to Step 23 |
| 16 | Connect a fused jumper between the cooling fan relay LOW connector terminals 30 and 87. Do the cooling fans run at low speed? | Go to Step 26 | Go to Step 17 |
| 17 | Disconnect the series/parallel fan series/parallel relay. Connect a fused jumper between the cooling fan relay LOW connector terminals 30 and 87. Connect a fused jumper between the cooling fan series/parallel relay connector terminals 30 and 87. Do the cooling fans run at low speed? | Go to Step 27 | Go to Step 18 |
| 18 | Inspect the wire between the cooling fan relay LOW connector terminal 87 to the main cooling fan connector terminal 2 for an open. Is the problem found? | Go to Step 22 | Go to Step 19 |
| 19 | Inspect the wire between the main cooling fan connector terminal 1 and the cooling fan control relay connector terminal 30 for an open. Is the problem found? | Go to Step 22 | Go to Step 20 |
| 20 | Inspect the wire between the cooling fan series/parallel relay connector terminal 87A and the auxiliary cooling fan connector terminal 2 for an open. Is the problem found? | Go to Step 22 | Go to Step 21 |
| 21 | Inspect for an open wire between the auxiliary cooling fan connector terminal 1 and ground. Is the problem found? | Go to Step 22 | Go to Step 29 |
| 22 | Repair the open wire as needed. Is the repair complete? | System OK | |
| 23 | Repair the open between the cooling fan relay LOW connector terminal 30 and the fuse EF3. Is the repair complete? | System OK | |
| 24 | Repair the open between the cooling fan relay LOW connector terminal 85 and the ignition switch. Is the repair complete? | System OK | |
| 25 | Repair the open wire between the cooling fan relay LOW connector terminal 86 and the ECM low cooling fan relay control circuit. Is the repair complete? | System OK | |
| 26 | Replace the cooling fan relay LOW. Is the repair complete? | System OK | |
| 27 | Replace the cooling fan series/parallel relay. Is the repair complete? | System OK | |
| 28 | Replace the main cooling fan. Is the repair complete? | System OK | |
| 29 | Replace the auxiliary cooling fan. Is the repair complete? | System OK | |
| 30 | Replace the ECM. Is the repair complete? | System OK | |
| 31 | Turn the ignition OFF. Disconnect the main cooling fan connector. Connect a test light between the main cooling fan connector terminal 2 and ground. Turn the A/C switch ON. Start the engine. Is the test light ON? | Go to Step 32 | Go to Step 12 |
| 32 | Turn the ignition OFF. Connect a test light between the main cooling fan connector terminal 1 and battery positive. Turn the A/C switch ON. Start the engine. Is the test light ON? | Go to Step 28 | Go to Step 17 |
| 33 | Turn the ignition OFF. Disconnect the cooling fan relay HI. Connect a test light between the cooling fan relay HI connector terminal 85 and ground. Turn the ignition ON. Is the test light ON? | Go to Step 34 | Go to Step 44 |
| 34 | Turn the ignition OFF. Connect a test light between the cooling fan relay HI connector terminal 30 and ground. Is the test light ON? | Go to Step 35 | Go to Step 45 |
| 35 | Disconnect the cooling fan series/parallel relay. Connect a test light between the cooling fan series/parallel relay connector terminal 85 and ground. Turn the ignition ON. Is the test light ON? | Go to Step 36 | Go to Step 46 |
| 36 | Turn the ignition OFF. Connect a test light between the cooling fan series/parallel relay connector terminal 87 and battery positive. Is the test light ON? | Go to Step 37 | Go to Step 47 |
| 37 | Connect the main cooling fan connector. Connect the cooling fan relay HI. Connect the cooling fan series/parallel relay. Disconnect the ECM connector. Connect a fused jumper between the ECM low cooling fan relay control circuit and ground. Connect a fused jumper between the ECM high cooling fan relay control circuit and ground. Turn the ignition ON. Do the cooling fans run at high speed? | Go to Step 30 | Go to Step 38 |
| 38 | Turn the ignition OFF. Inspect for an open wire between the cooling fan relay HI connector terminal 86 and the ECM high cooling fan relay control circuit and ground. Is the problem found? | Go to Step 22 | Go to Step 39 |
| 39 | Disconnect the cooling fan relay HI. Connect a test light between the cooling fan relay HI connector terminal 87 and battery positive. Is the test light ON? | Go to Step 40 | Go to Step 48 |
| 40 | Disconnect the ECM connector. Connect a fused jumper between the ECM high cooling fan relay control circuit and ground. Disconnect the cooling fan relay HI. Connect a test light between the cooling fan control relay connector terminal 86 and battery positive. Is the test light ON? | Go to Step 41 | Go to Step 49 |
| 41 | Connect the cooling fan control relay. Connect a fused jumper between the ECM high cooling fan relay control circuit and ground. Disconnect the cooling fan relay HI. Connect a fused jumper between the cooling fan relay HI connector terminals 30 and 87. Disconnect the low speed cooling fan relay. Connect a fused jumper between the low speed cooling fan relay connector terminals 30 and 87. Turn the ignition ON. Do the cooling fans run at high speed? | Go to Step 43 | Go to Step 42 |
| 42 | Turn the ignition OFF. Connect a fused jumper between the ECM high cooling fan relay control circuit and ground. Disconnect the cooling fan series/parallel relay. Connect a fused jumper between the cooling fan series/parallel relay connector terminals 30 and 87. Connect a fused jumper between the low speed cooling fan relay connector terminals 30 and 87. Turn the ignition ON. Do the cooling fans run at high speed? | Go to Step 27 | |
| 43 | Replace the cooling fan relay HI. Is the repair complete? | System OK | |
| 44 | Repair the open wire between the cooling fan relay HI connector terminal 85 and the ignition switch. Is the repair complete? | System OK | |
| 45 | Repair the open wire between the cooling fan relay HI connector terminal 30 and the battery. Is the repair complete? | System OK | |
| 46 | Repair the open wire between the cooling fan series/parallel relay connector terminal 85 and the ignition switch. Is the repair complete? | System OK | |
| 47 | Repair the open wire between the cooling fan series/parallel relay connector terminal 87 and ground. Is the repair complete? | System OK | |
| 48 | Repair the open wire between the cooling fan relay HI connector terminal 87 and the auxiliary cooling fan connector terminal 2. Is the repair complete? | System OK | |
| 49 | Repair the open wire between the cooling fan series/parallel relay connector terminal 85 and the ECM connector terminal K12. Is the repair complete? | System OK |
The numbers below refer to the step numbers on the diagnostic table.
- 4: This step, along with step 5, checks for the ability of the ECM to operate the cooling fans.
- 22: By directly grounding the ECM low cooling fan relay and high cooling fan relay control circuits, the cooling fan should run at high speed.
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Did you perform the Diagnostic System Check-Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle |
| 2 | Inspect the I/P fuse block fuse F18 for the 1.4L/1.5L application, or underhood fuse EF2 for the 1.2L. Replace the fuse as needed. Is the fuse OK? | Go to Step 3 | Go to Diagnostic Aids |
| 3 | Inspect the engine fuse block fuse EF3. Replace the fuse as needed. Is the fuse OK? | Go to Step 4 | Go to Diagnostic Aids |
| 4 | Turn the ignition OFF. Connect the scan tool to the data link connector (DLC). Start the engine. The cooling fan should run at low speed when the coolant temperature reaches 93°C (199°F). Does the cooling fan run at low speed? | Go to Step 5 | Go to Step 6 |
| 5 | Turn the ignition OFF. Connect a scan tool to the DLC. Start the engine. The cooling fan should run at high speed when the coolant temperature reaches 97°C (207°F). Does the cooling fan run at high speed? | System OK | Go to Step 22 |
| 6 | Turn the ignition OFF. Disconnect the engine control module (ECM) connector. Connect a fused jumper between the ECM low cooling fan relay control circuit and ground. Turn the ignition ON. Does the cooling fan run at low speed? | Go to Step 21 | Go to Step 7 |
| 7 | Turn the ignition OFF. Connect a fused jumper between the ECM low cooling fan relay control circuit and ground. Disconnect the cooling fan connector. Connect a test light between the cooling fan connector terminal 2 and ground. Turn the ignition ON. Is the test light ON? | Go to Step 8 | Go to Step 9 |
| 8 | Turn the ignition OFF. Connect a test light between the cooling fan connector terminal 1 and battery positive. Is the test light ON? | Go to Step 18 | Go to Step 17 |
| 9 | Turn the ignition OFF. Remove the jumper from the ECM low cooling fan control circuit. Using a test light, connect to ground, probe the low speed relay connector terminal 86. Turn the ignition ON. Is the test light ON? | Go to Step 10 | Go to Step 13 |
| 10 | Turn the ignition OFF. Connect a test light between the cooling fan relay LOW connector terminal 30 and ground. Is the test light ON? | Go to Step 11 | Go to Step 14 |
| 11 | Connect a test light between the cooling fan relay LOW connector terminal 87 and battery positive. Is the test light ON? | Go to Step 12 | Go to Step 16 |
| 12 | Connect a fused jumper between the ECM low cooling fan relay control circuit and ground. Connect a test light between the cooling fan relay LOW connector terminal 85 and battery positive. Is the test light ON? | Go to Step 19 | Go to Step 15 |
| 13 | Repair the open wire between the cooling fan relay LOW connector terminal 85 and the ignition voltage supply. Is the repair complete? | System OK | |
| 14 | Repair the open wire between the cooling fan relay LOW connector terminal 30 and the fuse EF3. Is the repair complete? | System OK | |
| 15 | Repair the open wire between the cooling fan relay LOW connector terminal 86 and the ECM low cooling fan relay control circuit. Is the repair complete? | System OK | |
| 16 | Inspect for an open wire between the cooling fan relay LOW connector terminal 87 and the cooling fan connector terminal 2. Is the problem found? | Go to Step 20 | Go to Step 17 |
| 17 | Inspect for an open wire between the cooling fan connector terminal 1 and ground. Is the problem found? | Go to Step 20 | Go to Step 18 |
| 18 | Replace the cooling fan. Refer to Engine Cooling Fan Replacement . Is the repair complete? | System OK | |
| 19 | Replace the cooling fan relay LOW. Is the repair complete? | System OK | |
| 20 | Repair the wire as needed. Is the repair complete? | System OK | |
| 21 | Replace the ECM. Is the repair complete | System OK | |
| 22 | Turn the ignition OFF. Disconnect the ECM connector. Connect a fused jumper between the ECM low cooling fan relay control circuit and ground. Connect a fused jumper between the ECM high cooling fan relay control circuit and ground. Turn the ignition ON. Does the cooling fan run at high speed? | Go to Step 21 | Go to Step 23 |
| 23 | Turn the ignition OFF. Disconnect the cooling fan relay HI. Connect a test light between the cooling fan relay high connector terminal 85 and ground. Turn the ignition ON. Is the test light ON? | Go to Step 24 | Go to Step 28 |
| 24 | Turn the ignition OFF. Connect a test light between the cooling fan relay HI connector terminal 30 and ground. Is the test light ON? | Go to Step 25 | Go to Step 29 |
| 25 | Connect a test light between the cooling fan relay HI connector terminal 87 and ground. Is the test light ON? | Go to Step 26 | Go to Step 30 |
| 26 | Connect a fused jumper between the ECM high cooling fan control circuit and ground. Connect a test light between the cooling fan relay HI connector terminal 86 and battery positive. Is the test light ON? | Go to Step 27 | Go to Step 31 |
| 27 | Replace the cooling fan relay HI. Is the repair complete? | System OK | |
| 28 | Repair the open wire between the cooling fan relay HI connector terminal 85 and the ignition switch voltage supply. Is the repair complete? | System OK | |
| 29 | Repair the open wire between the cooling fan relay HI connector terminal 30 and the fuse EF3. Is the repair complete? | System OK | |
| 30 | Repair the open wire between the cooling fan relay HI connector terminal 87 and the cooling fan connector terminal 2. Is the repair complete? | System OK | |
| 31 | Repair the open wire between the cooling fan relay HI connector terminal 86 and the ECM relay control circuit. Is the repair complete? | System OK |
Cooling System Description and Operation
The cooling system maintains the engine temperature at an efficient level during all engine operating conditions. When the engine is cold, the cooling system cools the engine slowly or not at all. This slow cooling of the engine allows the engine to warm up quickly.
The cooling system includes a radiator and recovery subsystem, cooling fans, a thermostat and housing, a coolant pump, and a coolant pump drive belt. The timing belt drives the coolant pump.
All components must function properly in order for the cooling system to operate. The coolant pump draws the coolant from the radiator. The coolant then circulates through water jackets in the engine block, the intake manifold, and the cylinder head. When the coolant reaches the operating temperature of the thermostat, the thermostat opens. The coolant then goes back to the radiator where it cools.
This system directs some coolant through the hoses to the heater core. This provides for heating and defrosting. The surge tank is connected to the radiator to recover the coolant displaced by expansion from the high temperatures. The surge tank maintains the correct coolant level.
The cooling system for this vehicle has no radiator cap or filler neck. The coolant is added to the cooling system through the surge tank.