Reference Information
Schematic Reference
Engine Cooling Schematics
Connector End View Reference
- «Component Connector End Views»(ref-299595-S18296060692008092400000)
- «Electrical Center Identification Views»(ref-299595-S05707746042008092400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-299596-S40031980912008092400000)
- «Connector Repairs»(ref-299596-S11637586662008092400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-299596-S35075552982008092400000)
- «Wiring Repairs»(ref-299596-S38795053442008092400000)
Scan Tool Reference
Control Module References for scan tool information
Circuit/System Verification
Ignition ON, command the relay ON and OFF with a scan tool. Feel or listen to verify that the relay turns ON and OFF with each command.
Repair Procedures
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Cooling Fan and Shroud Replacement (LE5, L61)»(ref-299633-S00615441552008092400000) or «Cooling Fan and Shroud Replacement (LNF)»(ref-299633-S09096239092008092400000)
- «Fan Shroud Replacement»(ref-299633-S35494730142008092400000)
- «Engine Control Module Replacement»(ref-299614-S32629922262008092400000) for the 2.2L engine
- «Engine Control Module Replacement»(ref-299615-S05884263262008092400000) for the 2.4L engine
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.
- «Cooling Fan and Shroud Replacement (LE5, L61)»(ref-299633-S00615441552008092400000) or «Cooling Fan and Shroud Replacement (LNF)»(ref-299633-S09096239092008092400000)
- «Control Module References»(ref-299597-S40606836452008092400000) for replacement, setup, and programming
Repair Verification
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.
Symptoms - Engine Cooling
| IMPORTANT | Review the system operation in order to familiarize yourself with the system functions. Refer to Cooling System Description and Operation . |
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections .
Schematic Reference
Engine Cooling Schematics
Connector End View Reference
- «Component Connector End Views»(ref-299595-S18296060692008092400000)
- «Electrical Center Identification Views»(ref-299595-S05707746042008092400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-299596-S40031980912008092400000)
- «Connector Repairs»(ref-299596-S11637586662008092400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-299596-S35075552982008092400000)
- «Wiring Repairs»(ref-299596-S38795053442008092400000)
Scan Tool Reference
Control Module References for scan tool information
- If DTC P0480 is set, perform that diagnostic first.
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, observe that the fan is not activated.
- «Cooling Fan and Shroud Replacement (LE5, L61)»(ref-299633-S00615441552008092400000) or «Cooling Fan and Shroud Replacement (LNF)»(ref-299633-S09096239092008092400000)
- «Fan Shroud Replacement»(ref-299633-S35494730142008092400000)
- «Engine Control Module Replacement»(ref-299614-S32629922262008092400000) for the 2.2L engine
- «Engine Control Module Replacement»(ref-299615-S05884263262008092400000) for the 2.4L engine
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, observe that the fan is not activated.
Schematic Reference
Engine Cooling Schematics
Connector End View Reference
Component Connector End Views
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-299596-S40031980912008092400000)
- «Connector Repairs»(ref-299596-S11637586662008092400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-299596-S35075552982008092400000)
- «Wiring Repairs»(ref-299596-S38795053442008092400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- If DTCs P0480, P0691, or P0692 are set, perform that diagnostic first.
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, observe that the fan is not activated. If the fan is activated, replace the cooling fan assembly.
Perform the Cooling Fan and Shroud Replacement (LE5, L61) or Cooling Fan and Shroud Replacement (LNF) after completing the diagnostic procedure.
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, observe that the fan is not activated.
Schematic Reference
Engine Cooling Schematics
Connector End View Reference
- «Component Connector End Views»(ref-299595-S18296060692008092400000)
- «Electrical Center Identification Views»(ref-299595-S05707746042008092400000)
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-299596-S40031980912008092400000)
- «Connector Repairs»(ref-299596-S11637586662008092400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-299596-S35075552982008092400000)
- «Wiring Repairs»(ref-299596-S38795053442008092400000)
Scan Tool Reference
Control Module References for scan tool information
- If DTC P0480 is set, then perform that diagnostic first.
- Ignition ON, command the relay ON and OFF with a scan tool. Observe to verify that the fan turns ON and OFF with each command.
- «Cooling Fan and Shroud Replacement (LE5, L61)»(ref-299633-S00615441552008092400000) or «Cooling Fan and Shroud Replacement (LNF)»(ref-299633-S09096239092008092400000)
- «Fan Shroud Replacement»(ref-299633-S35494730142008092400000)
- «Engine Control Module Replacement»(ref-299614-S32629922262008092400000) for the 2.2L engine
- «Engine Control Module Replacement»(ref-299615-S05884263262008092400000) for the 2.4L engine
Ignition ON, command the relay ON and OFF with a scan tool. Observe to verify that the fan turns ON and OFF with each command.
Schematic Reference
Engine Cooling Schematics
Connector End View Reference
Component Connector End Views
Description and Operation
Cooling Fan Description and Operation
Electrical Information Reference
- «Circuit Testing»(ref-299596-S40031980912008092400000)
- «Connector Repairs»(ref-299596-S11637586662008092400000)
- «Testing for Intermittent Conditions and Poor Connections»(ref-299596-S35075552982008092400000)
- «Wiring Repairs»(ref-299596-S38795053442008092400000)
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Control Module References for scan tool information
- If DTCs P0480, P0691, or P0692 are set, perform that diagnostic first.
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.
- «Cooling Fan and Shroud Replacement (LE5, L61)»(ref-299633-S00615441552008092400000) or «Cooling Fan and Shroud Replacement (LNF)»(ref-299633-S09096239092008092400000)
- «Control Module References»(ref-299597-S40606836452008092400000) for replacement, setup, and programming
- Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
- Ignition ON, command the cooling fan speed from 10-90 percent with a scan tool. The fan speed should transition with the commanded states.
Engine Overheating
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: The engine temperature lamp comes on and stays on, or temperature gage shows hot, or coolant overflows from the surge tank onto the ground while the engine is running. | |||
| 1 | Check for a loss of coolant. Refer to Loss of Coolant . Is there a loss of coolant? | Go to Step 2 | Go to Step 3 |
| 2 | Fill the system to the specified level. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Does the engine still overheat? | Go to Step 3 | System OK |
| 3 | Check for kinked or pinched surge tank hoses, especially at the radiator. Are any surge tank hoses kinked or pinched? | Go to Step 4 | Go to Step 5 |
| 4 | Relieve any kinks by rerouting the hoses. Replace the hoses, if necessary. Does the engine still overheat? | Go to Step 5 | System OK |
| 5 | Check for loose, missing, or damaged radiator air seals or deflectors. Are there any loose, missing, or damaged radiator air seals or deflectors? | Go to Step 6 | Go to Step 7 |
| 6 | Repair or replace any loose, missing, or damaged radiator air seals or deflectors. Does the engine still overheat? | Go to Step 7 | System OK |
| 7 | Check the coolant concentration. Does the coolant concentration test correctly? | Go to Step 9 | Go to Step 8 |
| 8 | Replace the coolant, if necessary. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Does the engine still overheat? | Go to Step 9 | System OK |
| 9 | IMPORTANT: Use the correct pressure cap. Check the system for loss of pressure.Is there a loss of pressure? | Go to Step 10 | Go to Step 11 |
| 10 | Repair any leaks, as necessary. Does the engine still overheat? | Go to Step 11 | System OK |
| 11 | Check for a faulty engine coolant temperature (ECT) sensor. Is the ECT sensor faulty? | Go to Step 12 | Go to Step 13 |
| 12 | Replace the ECT sensor. Refer to one of the following: Engine Coolant Temperature Sensor Replacement Engine Coolant Temperature Sensor Replacement Does the engine still overheat? | Go to Step 13 | System OK |
| 13 | Check the radiator for any air flow obstructions or bent fins. Is there any airflow obstruction or bent fins? | Go to Step 14 | Go to Step 15 |
| 14 | Remove or relocate add-on parts that block air flow to the radiator. Clean any debris from the radiator core. Does the engine still overheat? | Go to Step 15 | System OK |
| 15 | Check for any blocked cooling system passages. Are there any blocked cooling system passages? | Go to Step 16 | Go to Step 17 |
| 16 | Remove any obstruction. Flush the cooling system as required. Refer to Coolant System Flushing . Refill the coolant. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Does the engine still overheat? | Go to Step 17 | System OK |
| 17 | Check for an inoperative cooling fan. Is the cooling fan inoperative? | Go to Step 18 | Go to Step 19 |
| 18 | Replace the cooling fan. Refer to Cooling Fan and Shroud Replacement (LE5, L61) or Cooling Fan and Shroud Replacement (LNF) . Does the engine still overheat? | Go to Step 19 | System OK |
| 19 | Check for a thermostat that is stuck closed. Is the thermostat stuck closed? | Go to Step 20 | Go to Step 21 |
| 20 | Replace the thermostat. Refer to Engine Coolant Thermostat Replacement (LNF) or Engine Coolant Thermostat Replacement (L61, LE5) . Does the engine still overheat? | Go to Step 21 | System OK |
| 21 | Check for a faulty water pump. The impeller blades may be eroded or broken. Is the water pump faulty? | Go to Step 22 | |
| 22 | Replace the water pump. Refer to Water Pump Replacement (L61, LE5) or Water Pump Replacement (LNF) . Does the engine still overheat? | System OK | |
| IMPORTANT |
|---|
| Use the correct pressure cap. |
Loss of Coolant
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: The cooling system is losing coolant either internally or externally. | |||
| 1 | Were you sent here from Symptoms or another diagnostic table? | 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-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . 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 28 |
| 6 | Engine overheating can cause a loss of coolant. Is the engine overheating? | Go to Step 29 | 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 31 | 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 30 | Go to Step 10 |
| 10 | CAUTION: Refer to Moving Parts and Hot Surfaces Caution . 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 surge tank hose fittings The heater core The radiator The engine oil cooler Turbocharger Are any of the hoses, clamps or pipes leaking? | Go to Step 22 | 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 The engine oil cooler Turbocharger Are any of the listed components leaking? | Go to Step 22 | 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 22 | Go to Step 14 |
| 14 | Pressure test the coolant pressure cap. Refer to Pressure Cap Testing . Does the coolant pressure cap hold pressure? | Go to Step 16 | Go to Step 23 |
| 15 | Pressure test the coolant pressure cap. Refer to Pressure Cap Testing . Does the coolant pressure cap hold pressure? | Go to Step 32 | Go to Step 23 |
| 16 | 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 24 | Go to Step 17 |
| 17 | Add 30 ml (1 oz) of GM P/N 89022219 (Canadian P/N 89022220) coolant leak detection dye to the cooling system for each 15 liters (4 gallons) of coolant. Refer to Approximate Fluid Capacities . Start the vehicle and allow the engine to reach normal operating temperature. Shut the engine off. Use J 42220 Universal 12V Leak Detection Lamp to visually inspect the components listed in steps 11 and 12. See Special Tools . Are any leaks present? | Go to Step 22 | Go to Step 18 |
| 18 | Use J 42220 to inspect for the following conditions: See Special Tools . 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 24 | Go to Step 19 |
| 19 | Inspect the underside of the engine oil fill cap for a gray/white milky substance. Is there a milky substance on under the oil fill cap? | Go to Step 20 | Go to Step 21 |
| 20 | Inspect the engine oil fluid level indicator for a gray/white milky substance. Is there a milky substance on the engine oil fluid level indicator? | Go to Step 30 | Go to Step 21 |
| 21 | 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 25 | Go to Step 33 |
| 22 | Repair or replace the leaking component. Refer to the appropriate repair. Is the repair complete? | Go to Step 33 | |
| 23 | Replace the coolant pressure cap. Is the repair complete? | Go to Step 33 | |
| 24 | Replace the heater core. Refer to Heater Core Replacement . Is the repair complete? | Go to Step 33 | |
| 25 | 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 26 | Go to Step 27 |
| 26 | Replace the radiator. Refer to Radiator Replacement . Service the automatic transmission. Refer to Engine Coolant/Water in Transmission . Is the repair complete? | Go to Step 33 | |
| 27 | Install the cooler lines to the radiator. Is the action complete? | Go to Step 33 | |
| 28 | Repair the engine no crank condition. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate for the 2.0L, Engine Will Not Crank - Crankshaft Will Not Rotate for the 2.2L (L61) engine or Engine Will Not Crank - Crankshaft Will Not Rotate for the 2.4L (LE5) engine. Is the repair complete? | Go to Step 33 | |
| 29 | Repair the engine overheating condition. Refer to Engine Overheating . Is the repair complete? | Go to Step 33 | |
| 30 | Repair the engine internal coolant leak. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate or Coolant in Engine Oil for the 2.0L, Coolant in Combustion Chamber or Coolant in Engine Oil for the 2.2L (L61) engine or Coolant in Combustion Chamber or Coolant in Engine Oil for the 2.4L (LE5) engine. Is the repair complete? | Go to Step 33 | |
| 31 | Repair the engine knock. Refer to Lower Engine Noise, Regardless of Engine Speed for the 2.0L, Lower Engine Noise, Regardless of Engine Speed for the 2.2L (L61) engine or Lower Engine Noise, Regardless of Engine Speed for the 2.4L (LE5) engine. Is the repair complete? | Go to Step 33 | |
| 32 | Repair the combustion pressure in the cooling system problem. Refer to Coolant in Combustion Chamber for the 2.0L, Coolant in Combustion Chamber for the 2.2L (L61) engine or Coolant in Combustion Chamber for the 2.4L (LE5) engine. Is the repair complete? | Go to Step 33 | |
| 33 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
| CAUTION |
|---|
| Refer to Moving Parts and Hot Surfaces Caution . |
Electrical Information Reference
- «Circuit Testing»(ref-299596-S40031980912008092400000)
- «Connector Repairs»(ref-299596-S11637586662008092400000)
- «Wiring Repairs»(ref-299596-S38795053442008092400000)
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- «Coolant Heater Replacement (LNF)»(ref-299633-S31871133342008092400000) or «Coolant Heater Replacement (L61, LE5)»(ref-299633-S30490455572008092400000)
- «Coolant Heater Cord Replacement (LNF)»(ref-299633-S09092685562008092400000) or «Coolant Heater Cord Replacement (L61, LE5)»(ref-299633-S29054785122008092400000)
Engine Fails To Reach Normal Operating Temperature
| Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
| 1 | Check the coolant level in the radiator surge tank. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . 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. Refer to Coolant System Flushing . 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 (LNF) or Engine Coolant Thermostat Replacement (L61, LE5) . Does the engine still fail to reach normal operating temperature? | System OK |
Tools Required
J 26568 Coolant and Battery Fluid Tester
Filling Procedure
- Close the radiator drain cock by hand.
- Install the water pump drain plug (1) if removed during the draining process. Tighten: Tighten the plug to 22 N.m (16 lb in).
- Lower the vehicle.
- Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system until the coolant level reaches and maintains slightly above the cold fill line on the surge tank. Refer to «Approximate Fluid Capacities»(ref-299612-S16905767772008092400000) .
- Install the coolant pressure cap.
- Start the engine.
- Run the engine at 2,000-2,500 RPM for 3 minutes.
- Allow the engine to idle for 30 seconds.
- Shut the engine off.
- Top off the coolant as necessary.
- Fill the coolant reservoir to the cold fill line.
- Inspect the cooling system for leaks.
- Inspect the concentration of the coolant mixture using J 26568 .
- Rinse away any excess coolant from the engine and the engine compartment.
- Close the radiator drain cock by hand.
- Install the water pump drain plug if removed during the draining process (1). Tighten: Tighten the drain plug to 22 N.m (16 lb ft).
- Lower the vehicle.
- Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean, drinkable water to the cooling system until the coolant level reaches the COLD FILL mark. The system will fill slowly and may take up to 10 minutes to fill. A minimum of 5.5L of DEX-COOL needs to be installed to ensure proper water pump priming during the first thermocycle. Refer to «Approximate Fluid Capacities»(ref-299612-S16905767772008092400000) for the total capacity.
- Start the engine.
- Install the surge tank cap.
- Run the engine at idle for 5 minutes in PARK (P) (Automatic) or NEUTRAL (N) (Manual) with the parking brake on.
- Turn off the engine and allow it to cool and the system pressure to decrease.
- Remove the surge tank cap (1).
- Add coolant to the surge bottle to COLD FILL mark as necessary.
- Install the surge tank cap.
- Run the engine at idle for an additional 5 minutes.
- Turn off the engine and allow it to cool.
- Repeat as steps 9 through 13 as necessary until the level stabilizes at the COLD FILL mark.
- Inspect the cooling system for leaks.
- Rinse away any excess coolant from the engine and the engine compartment.
Radiator Cleaning
| CAUTION | NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. |
Note. 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.
Scheme 19
| Callout | Component Name |
|---|---|
| NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 2.2L engine or Air Cleaner Assembly Replacement for the 2.4L engine. IMPORTANT: Drain only the fluid from the radiator coolant recovery expansion tank. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . Disconnect the generator electrical connectors from the generator. Refer to Generator Replacement (With L61 and LE5) or Generator Replacement (With LNF) . | |
| 1 | Coolant Recovery Reservoir Bolt Tighten: 9 N.m (80 lb in) |
| 2 | Coolant Recovery Expansion Tank Assembly Tip: Use J 38185 to remove the coolant recovery hose from the coolant recovery reservoir. See Special Tools . |
| NOTE |
|---|
| Refer to Fastener Notice . |
| IMPORTANT |
|---|
| Drain only the fluid from the radiator coolant recovery expansion tank. |
Scheme 20
| Callout | Component Name |
|---|---|
| NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 2.2L engine or Air Cleaner Assembly Replacement for the 2.4L engine. Partially drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . | |
| 1 | Radiator Cap |
| 2 | Coolant Recovery Reservoir Hose Tip: Only remove the coolant recovery reservoir hose from the radiator fill neck tube. |
| 3 | Radiator Inlet - Front Hose Tip: Use J 38185 to reposition hose on the radiator inlet hose. See Special Tools . |
| 4 | Radiator Fill Tube Neck |
| 5 | Radiator Inlet - Rear Hose Tip: Use J 38185 to reposition hose on the radiator inlet hose. See Special Tools . |
| NOTE |
|---|
| Refer to Fastener Notice . |
Scheme 21
| Callout | Component Name |
|---|---|
| Preliminary Procedure Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . | |
| 1 | Radiator Outlet Hose Tip: Use J 38185 Hose Clamp Pliers to reposition the hose clamps. See Special Tools . |
Scheme 22
| Callout | Component Name |
|---|---|
| Preliminary Procedures: Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . | |
| 1 | Radiator Outlet Hose Procedure: Using J 38185 reposition the radiator outlet hose clamps. See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools . |
Scheme 23
| Callout | Component Name |
|---|---|
| Preliminary Procedures: Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LE5, L61) , Cooling System Draining and Filling (GE 47716 Fill) or Cooling System Draining and Filling (Static Fill-LNF) . | |
| 1 | Engine Oil Cooler Hose Procedure: Using J 38185 reposition the engine oil cooler hose clamps. See Special Tools . Special Tools: J 38185 Hose Clamp Pliers. See Special Tools . |
Scheme 24
| Callout | Component Name |
|---|---|
| NOTE: Refer to Fastener Notice . Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 2.2L engine or Air Cleaner Assembly Replacement for the 2.4L engine. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement . Remove the hood latch from the tie bar and set aside. Refer to Hood Primary and Secondary Latch Replacement . Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement . Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement . Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement . | |
| 1 | Fan Assembly, Engine Cooling - with Shroud Tip: Disconnect the cooling fan motor electrical connector. Remove the transmission line connector from the fan shroud. Lift the radiator out of the support bracket and pull toward the front of the vehicle. Lift up on the fan shroud assembly to release from the radiator. |
| NOTE |
|---|
| Refer to Fastener Notice . |
J 43651 Water Pump Holding Tool. See Special Tools .
Charge Air Cooler Cleaning
| CAUTION | NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. |
Note. 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 charge air cooler fins.
- Clean between the charge air cooler and condenser.
- Straighten any damaged cooling fins.
Cooling Fan Control
The engine cooling fan system consists of one cooling fan and one relay. The relay is powered by the battery positive voltage circuit and controlled by a switched ground from the engine control module (ECM).
During operation, the ECM supplies the ground path for the cool fan relay, through the cooling fan relay control circuit. This energizes the cool fan relay coil, closes the relay contacts, and supplies battery positive voltage from the cool fan fuse through the cooling fan motor supply voltage circuit to the cooling fan. The cooling fan motor is grounded through its own ground circuit.
When the request for fan activation is withdrawn, the fan may not turn OFF until the ignition switch is moved to the OFF position or the vehicle speed exceeds approximately 10 mph. This is to prevent a fan from cycling ON and OFF excessively at idle.
The engine cooling fan system consists of one cooling fan and two relays. The cooling fan has 2 windings in the motor, one winding is for low speed and the other winding is for high speed. Voltage is supplied to the relays from the 30 A cooling fan 1 and 30 A cooling fan 2 fuses. The engine control module (ECM) controls the low speed fan operation by grounding the cool fan 1 relay control circuit. When the cooling fan 1 relay is energized, voltage is delivered to the cooling fan low speed winding. The ECM controls the high speed fan operation by grounding the cool fan 2 relay control circuit. When the cooling fan 2 relay is energized, voltage is delivered to the cooling fan high speed winding. The cooling fan motor is grounded through its own ground circuit.
The PCM commands Low Speed Fans ON under the following conditions
- Engine coolant temperature (ECT) exceeds approximately 106°C (223°F).
- A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
- After the vehicle is shut off, the ECT at key-off is greater than 140°C (284°F) and system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.
The PCM commands High Speed Fans ON under the following conditions
- ECT reaches 110°C (230°F).
- A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
- When certain DTCs set
Engine Coolant Indicator(s)
The instrument panel cluster (IPC) illuminates the low coolant warning indicator when any of the following occur
- The body control module (BCM) detects a low coolant level condition for at least 30 seconds. The IPC receives a class 2 message from the BCM requesting illumination.
- The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds.
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.
Charge Air Cooling System (LNF Only)
The charge air cooling systems function is to reduce the temperature of the air charge that is heated during the turbocharged process which improves the efficiency of the turbocharged system. The charge air cooling system is a air-to-air system that uses a charge air cooling radiator located in front of the fan shroud to cool the air charge.
Cooling Cycle (LE5)
Coolant from the water pump is circulated through the water jackets in the cylinder block where the coolant absorbs the released heat.
The coolant also flows through the cylinder head gasket openings and into the cylinder head. The coolant flows through the water jackets surrounding the combustion chambers and valve seats where the coolant absorbs additional heat.
Coolant flows from the water pump into the radiator inlet port located on top of the radiator. From the radiator outlet, the coolant flows to the surge tank and to the thermostat assembly. The flow of coolant will either be stopped at the thermostat until the engine reaches normal operating temperature, or it will flow through the thermostat and back through the cooling system to the radiator where it will be cooled. At this point, the coolant flow cycle is completed.
Some coolant flow through the engine is directed through the heater core, then back to the engine. This provides the passenger compartment with heat and defrosting capability as the cooling system warms up.
Efficient operation of the cooling system requires proper functioning of all cooling system components.
Cooling Cycle (LNF)
Coolant from the water pump is circulated through the water jackets in the cylinder block and absorbs the released heat.
The coolant then flows through the cylinder head gasket openings and into the cylinder head. The coolant flows through the water jackets surrounding the combustion chambers and valve seats where the coolant absorbs additional heat.
Coolant flows from the water pump outlet to the radiator inlet port located on top of the radiator. From the radiator outlet, the coolant flows to both the engine oil cooler (EOC) and the thermostat housing.
- At the EOC, coolant flows through the EOC and is then directed to the thermostat housing and the surge tank.
- At the thermostat housing the flow of coolant will either be stopped by the thermostat until the engine reaches normal operating temperature, or it will flow through the thermostat and back through the cooling system to the radiator where it will be cooled.
Some coolant flow through the engine is directed through the heater core, then back to the engine. This provides the passenger compartment with heat and defrosting capability as the cooling system warms up.
Coolant flow is also directed to the turbocharger assembly to aid the turbocharger in temperature control and system performance. At this point, the coolant flow cycle is complete.
Efficient operation of the cooling system requires proper functioning of all cooling system components.
Coolant
The engine coolant is a solution made up of a 50-50 mixture of DEX-COOL and suitable drinking water. The coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the atmosphere.
Radiator
The radiator is a heat exchanger. It consists of a core and two tanks. The aluminum core is a tube and fin crossflow 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 right 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.
Pressure Cap
The pressure cap seals the cooling system. It contains a blow off or pressure valve and a vacuum or atmospheric valve. The pressure valve is held against its seat by a spring, which protects the radiator from excessive cooling system pressure. The vacuum valve is held against its seat by a spring, which permits opening of the valve to relieve vacuum created in the cooling system as it cools off. The vacuum, if not relieved, might cause the radiator and/or coolant hoses to collapse.
The pressure cap allows cooling system pressure to build up as the temperature increases. As the pressure builds, the boiling point of the coolant increases. Engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant is, the faster the heat transfers from the radiator to the cooler, passing air.
The pressure in the cooling system can get too high. When the cooling system pressure exceeds the rating of the pressure cap, it raises the pressure valve, venting the excess pressure.
As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open, allowing outside air into the surge tank. This equalizes the pressure in the cooling system with atmospheric pressure, preventing the radiator and coolant hoses from collapsing.
Surge Tank
The surge tank is a plastic tank that the pressure cap mounts onto. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an air space in the cooling system. The air space allows the coolant to expand and contract. The surge tank also provides a coolant fill point and a central air bleed location. During vehicle use, the coolant heats and expands. The coolant that is displaced by this expansion flows into the surge tank. As the coolant circulates, air is allowed to exit. This is an advantage to the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles.
Air Baffles and Seals
The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent recirculation of hot air for better hot weather cooling and A/C condenser performance.
Water Pump
The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is mounted on the pump shaft and consists of a series of flat or curved blades or vanes on a flat plate. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force.
The impeller shaft is supported by one or more sealed bearings. The sealed bearings never need to be lubricated. Grease cannot leak out, dirt and water cannot get in as long as the seal is not damaged or worn.
The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is driven by the crankshaft via the timing chain.
Thermostat
The thermostat is a coolant flow control component. It's purpose is to help regulate the operating temperature of the engine. It utilizes a temperature sensitive wax-pellet element. The element connects to a valve through a small piston. When the element is heated, it expands and exerts pressure against the small piston. This pressure forces the valve to open. As the element is cooled, it contracts. This contraction allows a spring to push the valve closed.
When the coolant temperature is below the rated thermostat opening temperature, the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up. After the coolant temperature reaches the rated thermostat opening temperature, the thermostat valve will open. The coolant is then allowed to circulate through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system, after it has opened. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.
Engine Oil Cooler
The engine oil cooler (EOC) is an auxiliary heat exchanger located on the left rear side of the engine. Numerous cooling plates inside the EOC help to dissipate heat and control engine oil temperature.
The engine oil pump forces the engine oil through the EOC cooler through an inlet pipe. The engine oil then flows through the EOC where heat is dissipated from the fluid back to the atmosphere. The engine oil is then pumped through the EOC return pipe, back to the engine.
Transmission Oil Cooler
The transmission oil cooler is a heat exchanger. It is located inside the left side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator.
The transmission oil pump, pumps the fluid through the transmission oil cooler line to the transmission oil cooler. The fluid then flows through the cooler where the engine coolant absorbs heat from the fluid. The fluid is then pumped through the transmission oil cooler return line, to the transmission.