Temperature Versus Resistance
| °C | °F | Sensor Resistance |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 100 | 212 | 155 |
| 90 | 194 | 208 |
| 80 | 176 | 283 |
| 70 | 158 | 392 |
| 60 | 140 | 552 |
| 50 | 122 | 793 |
| 45 | 113 | 958 |
| 40 | 104 | 1165 |
| 35 | 95 | 1425 |
| 30 | 86 | 1755 |
| 25 | 77 | 2176 |
| 20 | 68 | 2717 |
| 15 | 59 | 3428 |
| 10 | 50 | 4356 |
| 5 | 41 | 5578 |
| 0 | 32 | 7198 |
| 5 | 23 | 9362 |
| 10 | 14 | 12278 |
| 15 | 5 | 16229 |
| 20 | 4 | 21653 |
| 30 | 22 | 39631 |
| 40 | 40 | 75532 |
Temperature Versus Resistance
Reference Information
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
Circuit/System Verification
- Ignition ON.
- Verify the scan tool Radiator Coolant Temperature Sensor parameter is between -39 to + 120°C (-38 to +248°F) and changes with engine run time. If not between -39 to + 120°C (-38 to +248°F) or does not change Refer to Circuit/System Testing below. If between -39 to + 120°C (-38 to +248°F) and changes
- Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
- Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing below. If the DTC does not set
- All OK.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Engine Coolant Temperature Sensor Replacement (Radiator)»(ref-543849-S25773315122013042400000) , «Engine Coolant Temperature Sensor Replacement (Water Outlet)»(ref-543849-S12251411472013042400000) for radiator coolant temperature sensor replacement.
- «Engine Control Module Replacement»(ref-543850-S05549369532013042400000) for engine control module replacement, setup, and programming.
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P0117, P0118, P0597, P0598, or P0599 should not be set. If a DTC is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-543818-S30338367942013042400000) for further diagnosis.
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-543824-S32327120202013042400000) , «Cooling System Draining and Filling (GE-47716 Fill)»(ref-543824-S13480839732013042400000) , and «Loss of Coolant»(ref-543824-S27973101512013042400000) .
- Engine idling for 15 minutes with the A/C OFF.
- Command the engine coolant thermostat heater to 100 percent with a scan tool. Increase the engine speed to 3, 000 RPM. Observe the scan tool radiator coolant temperature sensor and ECT sensor parameters. The radiator coolant temperature sensor and the ECT sensor parameters should be within 20°C (68°F).
- Operate the vehicle within the conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Engine Coolant Temperature Sensor Replacement (Radiator)»(ref-543849-S25773315122013042400000) , «Engine Coolant Temperature Sensor Replacement (Water Outlet)»(ref-543849-S12251411472013042400000)
- «Engine Control Module Replacement»(ref-543850-S05549369532013042400000) for ECM replacement, setup, and programming
Schematic Reference
Engine Controls Schematics
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Engine Running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P00B6, P0117, P0118, P0597, P0598, and P0599 should not be set. If a DTC is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-543818-S30338367942013042400000) for further diagnosis.
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-543824-S32327120202013042400000) , «Cooling System Draining and Filling (GE-47716 Fill)»(ref-543824-S13480839732013042400000) , and «Loss of Coolant»(ref-543824-S27973101512013042400000) .
- Verify the engine cooling fan operates. Refer to «Cooling Fan Inoperative»(ref-543824-S23379894082013042400000) .
- Engine idling for 15 minutes with the A/C OFF.
- Command the Engine Coolant Thermostat Heater to 100 percent with a scan tool. Increase the engine speed to 3, 000 RPM. Observe the scan tool ECT sensor parameter. The temperature should decrease to less than 85°C (185°F).
- Operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Engine Coolant Thermostat Replacement
Schematic Reference
Engine Heating/Cooling Schematics
Connector End View Reference
- «COMPONENT CONNECTOR END VIEWS - INDEX»(ref-545331)
- «Electrical Center Identification Views»(ref-543862-S26143419802013042400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify an audible click is heard or felt from each cooling fan relay when commanding the cooling fan ON and OFF with a scan tool. If a click is not heard or felt at each of the relays Refer to Circuit/System Testing below. If a click is heard or felt at each of the relays
- Operate the vehicle within the Conditions for Running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
- Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing below. If the DTC does not set
- All OK.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Relay Replacement (Within an Electrical Center)»(ref-543836-S30353975992013042400000) , «Relay Replacement (Attached to Wire Harness)»(ref-543836-S08613956392013042400000)
- «Control Module References»(ref-543823-S31978628992013042400000) for ECM replacement, setup, and programming
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. «Loss of Coolant»(ref-543824-S27973101512013042400000) , and «Cooling System Draining and Filling (Static Fill)»(ref-543824-S32327120202013042400000) , «Cooling System Draining and Filling (GE-47716 Fill)»(ref-543824-S13480839732013042400000) If the coolant level is not correct Repair as necessary. If the coolant level is correct
- Ignition ON.
- Verify the parameters listed below do not display Malfunction when commanding the Engine Coolant Thermostat Heater ON and OFF with a scan tool. Engine Coolant Thermostat Heater Control Circuit Low Voltage Test Status Engine Coolant Thermostat Heater Control Circuit Open Test Status Engine Coolant Thermostat Heater Control Circuit High Voltage Test Status If Malfunction is displayed Refer to Circuit/System Testing below. If Malfunction is not displayed
- Operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
- Verify the DTC does not set. If any DTC sets Refer to Circuit/System Testing below. If the DTC does not set
- All OK.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Engine Coolant Thermostat Replacement»(ref-543824-S28496196582013042400000) for E41 engine coolant thermostat heater replacement.
- «Control Module References»(ref-543823-S31978628992013042400000) for engine control module, replacement, programming, and setup.
Schematic Reference
Engine Controls Schematics
Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Cooling System Description and Operation (1.4L LUV) , Cooling System Description and Operation (1.8L LUW and LWE)
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
Scan Tool Reference
Control Module References for scan tool information
- Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P00B6, P0117, or P0118 should not be set. If a DTC is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-543818-S30338367942013042400000) for further diagnosis.
- Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. Refer to «Cooling System Draining and Filling (Static Fill)»(ref-543824-S32327120202013042400000) , «Cooling System Draining and Filling (GE-47716 Fill)»(ref-543824-S13480839732013042400000) , and «Loss of Coolant»(ref-543824-S27973101512013042400000) .
- Engine idling for 15 min with the A/C OFF. Verify the engine cooling fan is not ON at all times.
- Command the Engine Coolant Thermostat Heater to 0 % with a scan tool. Increase the engine speed to 3, 000 RPM. Observe the scan tool ECT sensor parameter. The temperature should increase to greater than 102°C (215°F). If less than the specified value, replace the E41 engine coolant thermostat heater.
- Operate the vehicle within the conditions for running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Engine Coolant Thermostat Replacement
Identifying Intermittent Conditions
Many intermittent conditions occur with harness or connector movement due to engine torque, rough pavement, vibration or physical movement of a component. Refer to the following for a list to help isolate an intermittent condition
- Water intrusion in connectors, terminals, or components
- Poor connector mating
- Terminal contact
- High circuit or component resistance-High resistance can include any resistance, regardless of the amount, which can interrupt the operation of the component.
- Harness' that are routed too tight, or chaffed circuits
- High or low ambient temperatures
- High or low engine coolant temperatures
- High underhood temperatures
- Heat build up in components or circuits due to circuit resistance, poor terminal contact, or high electrical load
- High or low system voltage
- High vehicle load conditions
- Rough road surface
- Electro-magnetic interference (EMI)/circuit interference from relays, solenoids or other electrical surge
- Incorrect installation of non-factory, aftermarket, or after factory add on accessories
If an intermittent is detected, refer to Testing for Intermittent Conditions and Poor Connections for specific strategies in diagnosing intermittent conditions.
Schematic Reference
Engine Heating/Cooling Schematics
Connector End View Reference
- «COMPONENT CONNECTOR END VIEWS - INDEX»(ref-545331)
- «Electrical Center Identification Views»(ref-543862-S26143419802013042400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify that there are no cooling system DTCs set. If any DTCs are set Refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-543818-S30338367942013042400000) . If no DTCs are set
- Verify the scan tool parameters listed below display OFF. Cooling Fan Relay 1 Command Cooling Fan Relays 2 and 3 Command If a scan tool parameter displays ON Refer to Diagnostic Aids and «Symptoms - Engine Cooling»(ref-543824-S01529599662013042400000) for further diagnosis. If both scan tool parameters display OFF
- Verify that the fan is not activated. If the fan is operating Refer to Circuit/System Testing below. If the fan is OFF
- All OK.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Relay Replacement (Within an Electrical Center) , Relay Replacement (Attached to Wire Harness)
Schematic Reference
Engine Heating/Cooling Schematics
Connector End View Reference
- «COMPONENT CONNECTOR END VIEWS - INDEX»(ref-545331)
- «Electrical Center Identification Views»(ref-543862-S26143419802013042400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-543822-S09065750572013042400000)
- «Connector Repairs»(ref-543822-S34024840292013042400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-543822-S12370792452013042400000)
- «Wiring Repairs»(ref-543822-S31020379062013042400000)
Scan Tool Reference
Control Module References for scan tool information
- Ignition ON.
- Verify that DTC P0480, P0481, P0691, P0692, P0693, or P0694 is not set. If a DTC is set Refer to «DTC P0480, P0481, P0691, P0692, P0693, or P0694»(ref-543824-S42555728382013042400000) . If no DTC is set
- Verify that the cooling fan operates at low, medium, and high speed, when commanding the appropriate cooling fan relays ON and OFF with a scan tool. If the cooling fan does not operate at all speeds Refer to Circuit/System Testing below. If the cooling fan operates at all speeds
- All OK.
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Relay Replacement (Within an Electrical Center)»(ref-543836-S30353975992013042400000) , «Relay Replacement (Attached to Wire Harness)»(ref-543836-S08613956392013042400000)
- «Engine Coolant Fan Replacement»(ref-543824-S20530876372013042400000)
Engine Overheating
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: Either of the following conditions indicate a probable engine overheat condition. The engine temperature gauge is in the red (overheat) zone and/or the engine temperature indicator is ON. Hot engine coolant overflows from the coolant recovery reservoir and/or radiator cap onto the ground while the engine is running. | |||
| 1 | Inspect and fill the cooling system, as necessary. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE-47716 Fill) . Inspect the cooling system for leaks, as necessary. Repair the cooling system leaks, as necessary. Has the inspection/repair been performed? | Go to Step 2 | |
| 2 | Start the engine and allow the engine to run at approximately 1, 200 RPM. Use the Scan Tool in order to verify the overheat condition. Does the Scan Tool verify the engine overheat condition? | Go to Step 3 | Go to Diagnostic System Check - Vehicle |
| 3 | Verify that the cooling fans are operating properly. Repair the cooling fan system, as necessary. Does the engine still overheat? | Go to Step 4 | System OK |
| 4 | Perform the following inspections: Inspect the radiator and the A/C condenser cooling fins for debris or any other obstruction. Inspect the drive belt system and the drive belt tensioner for proper operation in order to ensure that the coolant pump is rotating properly. Inspect for loose, damaged and/or missing air deflector(s). Check for a pinched or kinked cooling system hose. Repair the systems as necessary. Does the engine still overheat? | Go to Step 5 | System OK |
| 5 | Inspect the thermostat for proper operation. Refer to Thermostat Diagnosis (1.8L LUW and LWE) , Thermostat Diagnosis (1.4L LUV) . Is the thermostat operating properly? | Go to Step 7 | Go to Step 6 |
| 6 | Replace the thermostat. Refer to Engine Coolant Thermostat Replacement . Does the engine still overheat? | Go to Step 7 | System OK |
| 7 | NOTE: Excessive coolant freeze point protection MAY cause the coolant to boil at low temperatures. Inspect for the proper coolant concentration (mixture). Correct the coolant concentration as necessary. Remove the radiator cap. Start the engine and inspect for a constant flow of air bubbles in the engine coolant. Is there a constant flow of air bubbles in the engine coolant? | Go to Step 8 | Go to Step 9 |
| 8 | The probable cause of the engine overheat is combustion chamber gasses leaking into the cooling system. This condition is usually caused by the following: A worn or damaged cylinder head gasket A worn or damaged cylinder head A worn and/or damaged engine block Verify this condition by inspecting the spark plug electrodes and porcelain surrounding the spark plug electrode for signs of coolant. Replace and/or repair the engine internal component(s), as necessary, in order to repair the engine internal coolant leak. Does the engine still overheat? | Go to Step 1 | System OK |
| 9 | The engine overheat may be caused by a cooling system blockage. Flush the cooling system. Refer to Coolant System Flushing Does the engine still overheat? | Go to Step 10 | System OK |
| 10 | NOTE: It is unlikely that the water pump is the cause of the overheat condition. If NONE of the cooling system passages are restricted, replace the coolant pump. Refer to Water Pump Replacement (1.8L LUW and LWE) , Water Pump Replacement (1.4L LUV) Does the engine still overheat? | Go to Step 1 | System OK |
| NOTE |
|---|
| Excessive coolant freeze point protection MAY cause the coolant to boil at low temperatures. |
| NOTE |
|---|
| It is unlikely that the water pump is the cause of the overheat condition. |
Engine Overheating
Loss of Coolant
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: The cooling system is losing coolant either internally or externally. Special Tools BO-42220 Universal 12V Leak Detection Lamp For equivalent regional tools, refer to Special Tools . | |||
| 1 | Are you sent here from Symptoms? | Go to Step 2 | Go to Symptoms - Engine Cooling |
| 2 | Repair any present DTCs. Refer to Diagnostic System Check - Vehicle . Is the action complete? | Go to Step 3 | |
| 3 | Inspect the coolant level. Is the coolant at the proper level? | Go to Step 5 | Go to Step 4 |
| 4 | Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE-47716 Fill) . Is the action complete? | Go to Step 5 | |
| 5 | If the engine is suspected to have a coolant leak into a cylinder, the coolant can hydraulically lock the engine. Does the engine crankshaft rotate? | Go to Step 6 | Go to Step 25 |
| 6 | Engine overheating can cause a loss of coolant. Is the engine overheating? | Go to Step 28 | Go to Step 7 |
| 7 | Extended operation with a low coolant level can cause engine internal component failure. Is the engine knocking? | Go to Step 30 | Go to Step 8 |
| 8 | Idle the engine at normal operating temperature. Inspect for heavy white smoke coming out of the exhaust pipe. Is a heavy white smoke present from the exhaust pipe? | Go to Step 9 | Go to Step 10 |
| 9 | Coolant in the exhaust system creates a distinctive, burning coolant odor in the exhaust. Condensation in the exhaust system can cause an odorless white smoke during engine warm up. Does the white smoke have a burning coolant type odor? | Go to Step 29 | Go to Step 10 |
| 10 | WARNING: Refer to Moving Parts and Hot Surfaces Warning . With the engine idling, inspect the coolant recovery system.Does the coolant recovery system discharge coolant while the engine is idling? | Go to Step 15 | Go to Step 11 |
| 11 | Visually inspect the hoses, pipes and hose clamps at the following locations: The coolant surge tank The heater core The radiator Are any of the hoses, clamps or pipes leaking? | Go to Step 21 | Go to Step 12 |
| 12 | Visually inspect the following components: The coolant pressure cap The core plugs The cylinder head gaskets The engine block The intake manifold The radiator The thermostat housing The water pump Are any of the listed components leaking? | Go to Step 21 | Go to Step 13 |
| 13 | Pressure test the cooling system. Refer to Cooling System Leak Testing . With the cooling system pressurized, visually inspect the components listed in steps 11 and 12. Are any leaks present? | Go to Step 21 | Go to Step 14 |
| 14 | Pressure test the coolant pressure cap. Does the coolant pressure cap hold pressure? | Go to Step 15 | Go to Step 22 |
| 15 | Inspect for the following conditions: A coolant smell inside of the vehicle Coolant in the HVAC module drain tube Coolant on the vehicle floor covering near the HVAC module Is coolant present? | Go to Step 23 | Go to Step 16 |
| 16 | Add 30 ml (1 oz) of Extended Life Coolant Leak Detection Dye to the cooling system for each 15 L (4 gal) of coolant. Refer to Approximate Fluid Capacities . Start the vehicle and allow the engine to reach normal operating temperature. Shut the engine off. Use BO 42220 detection lamp to visually inspect the components listed in steps 11 and 12. Are any leaks present? | Go to Step 21 | Go to Step 17 |
| 17 | Use BO 42220 detection lamp to inspect for the following conditions: Coolant dye in the HVAC module drain tube Coolant dye on the vehicle floor covering near the HVAC module Is coolant dye present? | Go to Step 23 | Go to Step 18 |
| 18 | Inspect the underside of the engine oil fill cap for a gray/white milky substance. Is a milky substance under the oil fill cap? | Go to Step 19 | Go to Step 20 |
| 19 | Inspect the engine oil fluid level indicator for a gray/white milky substance. Is a milky substance on the engine oil fluid level indicator? | Go to Step 29 | Go to Step 20 |
| 20 | Inspect the automatic transmission oil fluid level indicator, if equipped, for a gray/white milky substance. Is there a milky substance on the automatic transmission fluid level indicator? | Go to Step 24 | Go to Step 32 |
| 21 | Repair or replace the leaking component. Refer to the appropriate repair. Is the repair complete? | Go to Step 32 | |
| 22 | Replace the coolant pressure cap. Is the repair complete? | Go to Step 32 | |
| 23 | Replace the heater core. Refer to Heater Core Replacement . Is the repair complete? | Go to Step 32 | |
| 24 | Remove the transmission oil cooler lines from the radiator. Pressure test the cooling system. Refer to Cooling System Leak Testing . Inspect the transmission oil cooler for coolant. Is coolant present? | Go to Step 25 | Go to Step 26 |
| 25 | Replace the radiator. Refer to Radiator Replacement (1.4L LUV with Automatic Transmission) , Radiator Replacement (1.8L LUW and LWE) , Radiator Replacement (1.4L LUV with Manual Transmission) . Service the automatic transmission. Is the repair complete? | Go to Step 32 | |
| 26 | Install the cooler lines to the radiator. Is the action complete? | Go to Step 32 | |
| 27 | Repair the engine no crank condition. Is the repair complete? | Go to Step 32 | |
| 28 | Repair the engine overheating condition. Is the repair complete? | Go to Step 32 | |
| 29 | Repair the engine internal coolant leak. Is the repair complete? | Go to Step 32 | |
| 30 | Repair the engine knock. Is the repair complete? | Go to Step 32 | |
| 31 | Repair the combustion pressure in the cooling system problem. Is the repair complete? | Go to Step 32 | |
| 32 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
| WARNING |
|---|
| Refer to Moving Parts and Hot Surfaces Warning . |
Loss of Coolant
Engine Fails To Reach Normal Operating Temperature
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Check the coolant level in the radiator surge tank. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE-47716 Fill) . Is the coolant at the proper level? | Go to Step 3 | Go to Step 2 |
| 2 | Add coolant to the radiator surge tank as necessary. Does the engine still fail to reach normal operating temperatures? | Go to Step 3 | System OK |
| 3 | Check for a blockage in the coolant passages. Are there any blockages in the coolant passages? | Go to Step 4 | Go to Step 5 |
| 4 | Flush the cooling system or flow check the radiator. Does the engine still fail to reach normal operating temperatures? | Go to Step 5 | System OK |
| 5 | Check to see if the incorrect thermostat was installed or if it is stuck or sticks in the open position. Was the incorrect thermostat installed, or is it stuck or does it stick in the open position? | Go to Step 6 | |
| 6 | Replace the thermostat. Refer to Engine Coolant Thermostat Replacement . Does the engine still fail to reach normal operating temperature? | System OK |
Engine Fails To Reach Normal Operating Temperature
Fill Procedure
- Close the radiator drain plug.
- Lower the vehicle.
- Vehicle should be level.
- Loosen the vent screw (1) on the radiator.
- Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water to the bottom line of the bleed nozzle on the coolant surge tank (1). When the coolant level stabilizes, add enough coolant to reach the bottom line of the down pipe hole (black arrow).
- Start the engine. After the engine starts, verify that the coolant level reaches the bottom line of the down pipe hole (black arrow).
- Install the surge tank cap.
- Warm up the engine. NOTE: If the heater core has been replaced, let the engine run for 2 minutes at 2.000-2.500 RPM. This ensures complete venting of the cooling system. Run at 2, 500 RPM until the engine cooling fan turns ON.
- Turn the engine OFF and allow the engine to cool down.
- Remove the surge tank cap.
- Check the coolant level and fill to the "COLD" mark if necessary (1).
- Inspect the concentration of the engine coolant, using GE-26568 tester.
- Install the surge tank cap.
- Rinse away any excess coolant from the engine and the engine compartment.
Radiator Cleaning
| WARNING | NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. |
| CAUTION | The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. |
- Some conditions may require the use of warm water and a mild detergent.
- Clean the A/C condenser fins.
- Clean between the A/C condenser and radiator.
- Clean the radiator cooling fins.
- Straighten any damaged cooling fins.
Repair Procedure
- Pressure test the cooling system. Refer to «Cooling System Leak Testing»(ref-543824-S27420175482013042400000) . If the radiator is not leaky, perform the following procedure.
- Remove the radiator. Refer to «Radiator Replacement (1.4L LUV with Automatic Transmission)»(ref-543824-S30035127722013042400000) , «Radiator Replacement (1.8L LUW and LWE)»(ref-543824-S22345098072013042400000) , «Radiator Replacement (1.4L LUV with Manual Transmission)»(ref-543824-S13950719352013042400000) .
- Grind the fracture surface (1) with a proper tool.
- Drill a hole in the center of the fractured surface, using a 6 mm (0.24 in) drill.
- Install the new radiator mounting pin (2). Install the nut (3). NOTE: The bolt should not be longer than 35 mm (1.38 in). Install the radiator mounting pin (2) with the bolt (1).
- Tighten the bolt 5 N.m (44 lb in).
- Install the radiator. Refer to «Radiator Replacement (1.4L LUV with Automatic Transmission)»(ref-543824-S30035127722013042400000) , «Radiator Replacement (1.8L LUW and LWE)»(ref-543824-S22345098072013042400000) , «Radiator Replacement (1.4L LUV with Manual Transmission)»(ref-543824-S13950719352013042400000) .
Radiator and Charge Air Cooler Bracket Repair
- Remove the radiator. Refer to «Radiator Replacement (1.4L LUV with Automatic Transmission)»(ref-543824-S30035127722013042400000) , «Radiator Replacement (1.8L LUW and LWE)»(ref-543824-S22345098072013042400000) , «Radiator Replacement (1.4L LUV with Manual Transmission)»(ref-543824-S13950719352013042400000) .
- Drill hole in the charge air cooler bracket and radiator bracket (2) using a 7 mm (0.28 in) drill.
- Install the j-clip (3) to the radiator.
- Install the radiator. Refer to «Radiator Replacement (1.4L LUV with Automatic Transmission)»(ref-543824-S30035127722013042400000) , «Radiator Replacement (1.8L LUW and LWE)»(ref-543824-S22345098072013042400000) , «Radiator Replacement (1.4L LUV with Manual Transmission)»(ref-543824-S13950719352013042400000) .
- Install the repair bolt (1) with locking compound and tighten to 5 N.m (45 lb in).
Scheme 18
| Callout | Component Name |
|---|---|
| Preliminary Procedure Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement . | |
| 1 | Radiator Lower Bracket Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Procedure Secure the radiator. Tighten 22 N.m (16 lb ft) |
| 2 | Radiator Lower Bracket |
| CAUTION |
|---|
| Refer to Fastener Caution . |
Radiator Lower Bracket Replacement
Scheme 19
| Callout | Component Name |
|---|---|
| Preliminary Procedures Remove the engine cooling fan shroud. Refer to Engine Coolant Fan Replacement . | |
| 1 | Engine Coolant Fan Resistor Mount |
| 2 | Engine Coolant Fan Resistor Mount Bolt CAUTION: Refer to Fastener Caution . Procedure In case of a broken engine coolant fan resistor mount use this repair procedure. Tighten 5 N.m (44 lb in) |
| CAUTION |
|---|
| Refer to Fastener Caution . |
Engine Coolant Fan Resistor Mount Repair
Radiator
The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin cross-flow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere. The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core. The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes the drain cock and drain cock seal. The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.
Surge Tank
The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an air space in the cooling system that allows the coolant to expand and contract. The surge tank provides a coolant fill point and a central air bleed location. During vehicle use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant circulates, any air is allowed to bubble out. Coolant without air bubbles absorbs heat much better than coolant with bubbles.
Cooling Fan
The cooling fan is mounted behind the radiator in the engine compartment. The engine cooling fan is driven by electric power. The cooling fan draws air through the radiator to improve the transfer of heat from the coolant to the atmosphere. As the fan blades spin, they increase the flow of air across the radiator core and across the condenser on air condition (A/C) equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds.
The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly.
Scheme 20
Note. See arrows for coolant flow order. Notice the port between cylinder head and thermostat housing, as well as the port between cylinder block and water pump.
The cooling system consists of the following components
- Throttle Body (1)
- Heater (2)
- Surge Tank (3)
- Engine Coolant Thermostat Housing (4)
- Radiator (5)
- Cooling Fan (6)
- Engine Oil Cooler Housing (7)
- Water Pump (8)
- Cylinder Head / Cylinder Block (9)
Scheme 21
Water pump is a component of the engine cooling system and circulated the coolant from each cooling circuit components. This water pump consists of sealing, bearing, pulley (3) and housing (2) and is driven by the crankshaft with the back of timing belt to loose noise to water pump pulley. Water pump apply drain hole cup to cap to prevent coolant leakage for customers. Water pump is not open impeller type but closed plastic impeller type to increase the cooling efficiency.
Scheme 22
Thermostat controls the flow of coolant and is mounted to the cylinder head. The thermostat contains a wax pellet (7) that expands and contracts based on the coolant temperature, which will mechanically move the main spring and a sealing disc to control the flow of coolant. The thermostat will begins to open electrically at 90°C (194°F) and will fully open mechanically at 105°C (221°F).
The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin cross-flow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere. The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core. The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes the drain cock and drain cock seal. The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.
The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an air space in the cooling system that allows the coolant to expand and contract. The surge tank provides a coolant fill point and a central air bleed location. During vehicle use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant circulates, any air is allowed to bubble out. Coolant without air bubbles absorbs heat much better than coolant with bubbles.
The cooling fans are mounted behind the radiator in the engine compartment. The engine cooling fan is driven by electric power. The cooling fan draws air through the radiator to improve the transfer of heat from the coolant to the atmosphere. As the fan blades spin, they increase the flow of air across the radiator core and across the condenser on air condition (A/C) equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds.