Cooling Fan - Right
| Connector Part Information OEM: 12033769 Service: 12101917 Description: 2-Way F Metri-Pack 630 Series Sealed Pull-to-Seat (BK) |
Cooling System Connector End Views
| Pin | Wire Color | Circuit No. | Function |
|---|---|---|---|
| A | BK | 450 | Ground |
| B | GY | 532 | Cooling Fan Motor Supply Voltage |
Cooling Fan - Right
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.
Engine Coolant Temperature Indicator Always On
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle |
| 2 | Start the engine. Does the engine coolant temperature (ECT) indicator illuminate? | Go to Step 3 | Go to Testing for Intermittent Conditions and Poor Connections |
| 3 | With the scan tool, observe the engine coolant temperature parameter in the powertrain control module (PCM) or engine control module (ECM) data list. Does the scan tool indicate that the coolant temperature is within the temperature range shown on the temperature gage? | Go to Engine Overheating | Go to Step 4 |
| 4 | Replace the instrument panel cluster (IPC). Refer to Control Module References for replacement, setup and programming. Did you complete the repair? | Go to Step 5 | |
| 5 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
Engine Coolant Temperature Indicator Always On
Low Engine Coolant Indicator Always On
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics Connector End View Reference: Cooling System Connector End Views DEFINITION: The low coolant level display is always ON when the key is in the ON position. | |||
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle in Vehicle DTC Information |
| 2 | Verify the coolant level is at the proper level in the surge tank. Turn ON the ignition, with the engine OFF. Is the low coolant message displayed on the driver information center (DIC)? | Go to Step 3 | Go to Testing for Electrical Intermittents in Wiring Systems |
| 3 | Turn OFF the ignition. Disconnect the coolant level sensor. Inspect the ground circuit for an open or high resistance at the coolant level sensor connector. Did you find and correct the condition? | Go to Step 10 | Go to Step 4 |
| 4 | Turn ON the ignition, with the engine OFF. Inspect the control circuit at the coolant level sensor connector for a 12-volt signal. Is 12 volts present on the control circuit? | Go to Step 6 | Go to Step 5 |
| 5 | Inspect the control circuit of the low coolant sensor for an open or short to voltage. Refer to Wiring Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 10 | Go to Step 8 |
| 6 | Inspect for poor connections at the coolant level sensor. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 10 | Go to Step 7 |
| 7 | Replace the coolant level sensor. Refer to Surge Tank Replacement . Did you complete the replacement? | Go to Step 10 | |
| 8 | Inspect for poor connections at the Body Control Module (BCM). Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 10 | Go to Step 9 |
| 9 | Replace the BCM. Refer to Control Module References in Computer/Integrating Systems for replacement, setup and programming. Did you complete the replacement? | Go to Step 10 | |
| 10 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 3 |
Low Engine Coolant Indicator Always On
Cooling Fan Always On
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics HVAC Schematics in HVAC Systems - Manual Connector End View Reference: Cooling System Connector End Views HVAC Connector End Views in HVAC Systems - Manual DEFINITION: The engine cooling fan motor runs continuously in high or low speed. | |||
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle in Vehicle DTC Information |
| 2 | Turn ON the ignition, with the engine OFF. Are one or both cooling fans ON? | Go to Step 3 | Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems |
| 3 | Are both cooling fans running continuously? | Go to Step 4 | Go to Step 6 |
| 4 | Are both fans running continuously in high speed? | Go to Step 5 | Go to Step 7 |
| 5 | Test the low reference circuit of the A/C refrigerant pressure sensor for an open. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. | Go to Step 18 | Go to Step 14 |
| 6 | Remove the cooling fan s/p relay. Did the right cooling fan turn OFF? | Go to Step 10 | Go to Step 8 |
| 7 | Remove the cooling fan 1 relay. Did the cooling fans turn OFF? | Go to Step 12 | Go to Step 9 |
| 8 | Remove the cooling fan 2 relay. Did the right cooling fan turn OFF? | Go to Step 13 | Go to Step 11 |
| 9 | Repair the short to voltage in the left cooling fan motor supply voltage circuit. Refer to Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 18 | |
| 10 | Repair the short to voltage in the left cooling fan motor low reference circuit. Refer to Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 18 | |
| 11 | Repair the short to voltage in the right cooling fan motor supply voltage circuit. Refer to Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 18 | |
| 12 | Inspect for poor connections at the cool fan 1 relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 18 | Go to Step 15 |
| 13 | Inspect for poor connections at the cool fan 2 relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 18 | Go to Step 16 |
| 14 | Inspect for poor connections at the A/C refrigerant pressure sensor. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 18 | Go to Step 17 |
| 15 | Replace the cool fan 1 relay. Did you complete the replacement? | Go to Step 18 | |
| 16 | Replace the cool fan 2 relay. Did you complete the replacement? | Go to Step 18 | |
| 17 | Replace the A/C refrigerant pressure sensor. Refer to Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement in Heating, Ventilation and Air Conditioning. Did you complete the replacement? | Go to Step 18 | |
| 18 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
Cooling Fan Always On
Cooling Fan Inoperative
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics Connector End View Reference: Cooling System Connector End Views DEFINITION: One or both cooling fan motors are inoperative in either high, low or both speeds. | |||
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle |
| 2 | Install a scan tool. Turn ON the ignition, with the engine OFF. With a scan tool, command the Fan Control Relay 1 ON and OFF. Do the low speed engine cooling fans turn ON and OFF with each command? | Go to Step 3 | Go to Step 4 |
| 3 | IMPORTANT: A 3 second delay occurs before the powertrain control module (PCM) or engine control module (ECM) changes the cooling fan speed. With a scan tool, command the Fan Control Relay 2 and 3 ON and OFF.Do the high speed engine cooling fans turn ON and OFF with each command? | Go to Testing for Intermittent Conditions and Poor Connections | Go to Step 6 |
| 4 | IMPORTANT: Do NOT remove the jumper wire that you will be connecting until your testing is completed. If the cool fan 1 fuse opens when you connect the jumper wire, repair the cooling fan motor supply voltage circuit of the left cooling fan motor for a short to ground. Disconnect the cool fan 1 relay. Connect a jumper wire between the battery positive voltage circuit and the cooling fan motor supply voltage circuit of the cool fan 1 relay. Do both cooling fans operate in low speed? | Go to Step 14 | Go to Step 5 |
| 5 | Disconnect the S/P fan relay. With a test lamp connected to a good ground, probe the cooling fan low reference circuit at the S/P fan relay. Does the test lamp illuminate? | Go to Step 9 | Go to Step 8 |
| 6 | Does the left cooling fan operate at high speed? | Go to Step 16 | Go to Step 7 |
| 7 | Inspect the ground circuit of the S/P fan relay for an open or high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 15 |
| 8 | Install the S/P fan relay. Disconnect the left cooling fan electrical connector. With a test lamp connected to a good ground, probe the cooling fan motor supply voltage circuit at the left cooling fan motor connector. Does the test lamp illuminate? | Go to Step 12 | Go to Step 13 |
| 9 | Install the S/P fan relay. Disconnect the right cooling fan motor connector. With a test lamp connected to a good ground, probe the cooling fan motor supply voltage circuit at the right cooling fan connector. Does the test lamp illuminate? | Go to Step 11 | Go to Step 10 |
| 10 | Inspect the cooling fan motor supply voltage circuit for an open or high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 15 |
| 11 | Inspect the ground circuit of the right cooling fan for an open or high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 18 |
| 12 | Inspect the cooling fan low reference circuit for an open or high resistance. Refer to Circuit Testing and Wiring Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 17 |
| 13 | Inspect the cooling fan motor supply voltage circuit of the left cooling fan for an open or high resistance. Refer to Circuit Testing Wiring Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 19 |
| 14 | Inspect for poor connections at the cool fan 1 relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 20 |
| 15 | Inspect for poor connections at the S/P fan relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 21 |
| 16 | Inspect for poor connections at the cool fan 2 relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 22 |
| 17 | Inspect for poor connections at the harness connector of the left cooling fan. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 23 |
| 18 | Inspect for poor connections at the harness connector of the right cooling fan. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | Go to Step 25 | Go to Step 24 |
| 19 | Repair the battery positive voltage circuit for an open or high resistance. Refer to Wiring Repairs . Did you complete the repair? | Go to Step 25 | |
| 20 | Replace the cool fan 1 relay. Did you complete the replacement? | Go to Step 25 | |
| 21 | Replace the S/P fan relay. Did you complete the replacement? | Go to Step 25 | |
| 22 | Replace the cool fan 2 relay. Did you complete the replacement? | Go to Step 25 | |
| 23 | Replace the left cooling fan. Refer to Cooling Fan and Shroud Replacement . Did you complete the replacement? | Go to Step 25 | |
| 24 | Replace the right cooling fan. Refer to Cooling Fan and Shroud Replacement . Did you complete the replacement? | Go to Step 25 | |
| 25 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 3 |
| IMPORTANT |
|---|
| A 3 second delay occurs before the powertrain control module (PCM) or engine control module (ECM) changes the cooling fan speed. |
| IMPORTANT |
|---|
| Do NOT remove the jumper wire that you will be connecting until your testing is completed. If the cool fan 1 fuse opens when you connect the jumper wire, repair the cooling fan motor supply voltage circuit of the left cooling fan motor for a short to ground. |
Cooling Fan Inoperative
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 Engine Overheating . Is there a loss of coolant? | Go to Step 2 | Go to Step 3 |
| 2 | Fill the system to the specified level. Refer to Draining and Filling Cooling System . 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 Draining and Filling Cooling System . 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 (ECT) Sensor Replacement Engine Coolant Temperature (ECT) Sensor Replacement Engine Coolant Temperature (ECT) 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 Flushing . Refill the coolant. Refer to Draining and Filling Cooling System . 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 . 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 Thermostat Replacement (2.4L) , Thermostat Replacement (3.5L) or Thermostat Replacement (3.9L) . 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 (2.4L) , Water Pump Replacement (3.5L) or Water Pump Replacement (3.9L) . Does the engine still overheat? | System OK | |
| IMPORTANT |
|---|
| Use the correct pressure cap. |
Engine Overheating
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 6 | Go to Step 4 |
| 4 | Fill the cooling system to the proper level. Refer to Draining and Filling Cooling System . 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 26 |
| 6 | Engine overheating can cause a loss of coolant. Is the engine overheating? | Go to Step 27 | 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 29 | 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 28 | Go to Step 10 |
| 10 | With the engine idling, inspect the surge tank. Does the surge tank 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: Coolant surge tank Heater core Radiator Are any of the hoses, clamps or pipes leaking? | Go to Step 20 | 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 20 | 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 20 | 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 21 |
| 15 | Pressure test the coolant pressure cap. Refer to Pressure Cap Testing . Does the coolant pressure cap hold pressure? | Go to Step 30 | Go to Step 21 |
| 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 22 | Go to Step 17 |
| 17 | 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 18 | Go to Step 19 |
| 18 | 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 28 | Go to Step 19 |
| 19 | 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 23 | Go to Step 31 |
| 20 | Repair or replace the leaking component. Refer to the appropriate repair. Is the repair complete? | Go to Step 31 | |
| 21 | Replace the coolant pressure cap. Is the repair complete? | Go to Step 31 | |
| 22 | Replace the heater core. Refer to Heater Core Replacement . Is the repair complete? | Go to Step 31 | |
| 23 | Remove the transmission oil cooler lines from the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting for the 4T40-E/4T45-E automatic transaxle or Transmission Fluid Cooler Line Quick Connect Fitting for the 4T65-E automatic transaxle. Pressure test the cooling system. Refer to Cooling System Leak Testing . Inspect the transmission oil cooler for coolant. Is coolant present? | Go to Step 24 | Go to Step 25 |
| 24 | Replace the radiator. Refer to Radiator Replacement (LE5) or Radiator Replacement (LX9, LZ9) . Service the automatic transmission. Refer to Engine Coolant/Water in Transmission for the 4T40-E/4T45-E automatic transaxle or Engine Coolant/Water in Transmission for the 4T65-E automatic transaxle. Is the repair complete? | Go to Step 31 | |
| 25 | Install the cooler lines to the radiator. Is the action complete? | Go to Step 31 | |
| 26 | Repair the engine no crank condition. Refer to the appropriate procedure: Engine Will Not Crank - Crankshaft Will Not Rotate for the 2.4L engine Engine Will Not Crank - Crankshaft Will Not Rotate for the 3.5L engine Engine Will Not Crank - Crankshaft Will Not Rotate for the 3.9L engine Is the repair complete? | Go to Step 31 | |
| 27 | Repair the engine overheating condition. Refer to Engine Overheating . Is the repair complete? | Go to Step 31 | |
| 28 | Repair the engine internal coolant leak. Refer to the appropriate procedure: Coolant in Combustion Chamber or Coolant in Engine Oil for the 2.4L engine Coolant in Combustion Chamber or Coolant in Engine Oil for the 3.5L engine Coolant in Engine Oil or Coolant in Combustion Chamber for the 3.9L engine Is the repair complete? | Go to Step 31 | |
| 29 | Repair the engine knock. Refer to the appropriate procedure: Lower Engine Noise, Regardless of Engine Speed for the 2.4L engine Lower Engine Noise, Regardless of Engine Speed for the 3.5L engine Lower Engine Noise, Regardless of Engine Speed for the 3.9L engine Is the repair complete? | Go to Step 31 | |
| 30 | Repair the combustion pressure in the cooling system problem. Refer to the appropriate procedure: Coolant in Combustion Chamber for the 2.4L engine Coolant in Combustion Chamber for the 3.5L engine Coolant in Combustion Chamber for the 3.9L engine Is the repair complete? | Go to Step 31 | |
| 31 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
Loss of Coolant
Coolant Heater Inoperative
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: The coolant heater does not warm the engine coolant properly. | |||
| 1 | Did you perform the necessary inspections? | Go to Step 2 | Go to Symptoms - Engine Cooling |
| 2 | Test the engine coolant heater power supply cord for an open or short to ground. Refer to Circuit Testing in Wiring Systems. Did you find a condition? | Go to Step 3 | Go to Step 4 |
| 3 | Replace the engine coolant heater power supply cord. Refer to Coolant Heater Cord Replacement (2.4L) or Coolant Heater Cord Replacement (3.5L) or Coolant Heater Cord Replacement (3.9L) . Did you complete the replacement? | Go to Step 6 | |
| 4 | Inspect for poor connections at the harness connector of the engine coolant heater. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 6 | Go to Step 5 |
| 5 | Replace the engine coolant heater. Refer to Coolant Heater Replacement (2.4L) or Coolant Heater Replacement (3.5L and 3.9L) . Did you complete the replacement? | Go to Step 6 | |
| 6 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
Coolant Heater Inoperative
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 Draining and Filling Cooling System . 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 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 Thermostat Replacement (2.4L) , Thermostat Replacement (3.5L) or Thermostat Replacement (3.9L) . Does the engine still fail to reach normal operating temperature? | System OK |
Engine Fails To Reach Normal Operating Temperature
Tools Required
- J 24460-01 Cooling System Pressure Tester. See «Special Tools»(ref-243023-S04058732852006082100000) .
- J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools»(ref-243023-S04058732852006082100000) .
- J 24460-01 Cooling System Pressure Tester. See «Special Tools»(ref-243023-S04058732852006082100000) .
- J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools»(ref-243023-S04058732852006082100000) .
J 26568 Coolant and Battery Fluid Tester. See Special Tools .
Fill Procedure
- Install the engine block coolant drain plugs. Refer to the appropriate procedure: «Engine Block Assemble»(ref-243010-S16902653652006082100000) for the 2.4L engine. «Engine Block Assemble»(ref-243014-S10426377552006082100000) for the 3.5L engine. «Engine Block Assemble»(ref-243015-S18435419192006082100000) for the 3.9L engine.
- Close the radiator drain plug.
- Lower the vehicle.
- Vehicle should be level.
- Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Capacities - Approximate Fluid»(ref-243030-S33748577392006082100000) .
- For the 3.5L (LX9) engine only, unscrew the coolant bleed screw on the engine until coolant comes out of the bleed screw.
- For the 3.5L (LX9) engine only, close the bleed screw.
- Add coolant until the level stabilizes at the weld seam on the surge tank.
- Install the surge tank cap.
- Start the engine and run at 2,000 RPM until the engine cooling fans turn ON.
- Remove the surge tank cap.
- Refill to the weld seam on the surge tank.
- Install the surge tank cap.
- Inspect the concentration of the engine coolant using J 26568 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Rinse away any excess coolant from the engine and the engine compartment.
J 26568 Coolant and Battery Fluid Tester. See Special Tools .
Note. The procedure below must be followed. Improper coolant level could result in a low or high coolant level condition, causing engine damage.
- Install the engine block coolant drain plugs. Refer to «ENGINE BLOCK ASSEMBLE»(ref-243010-S16902653652006082100000) for the 2.4L engine.
- Close the radiator drain plug.
- Lower the vehicle.
- Vehicle should be level.
- Slowly add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Capacities - Approximate Fluid»(ref-243030-S33748577392006082100000) .
- Start the engine. The coolant level in the surge tank will drop.
- Continue filling the surge tank as necessary to maintain the level at the cold fill mark.
- When the coolant in the upper radiator hose feels warm, install the surge tank cap.
- Continue to run the engine at 2,000 RPM until the engine cooling fans turn ON.
- Let the engine idle for 30 seconds.
- Turn the engine OFF and allow the engine to cool down.
- Adjust the coolant level.
- Inspect the concentration of the engine coolant using J 26568 .
- Rinse away any excess coolant from the engine and the engine compartment.
- J 26568 Coolant and Battery Fluid Tester. See «Special Tools»(ref-243023-S04058732852006082100000) .
- J 42401 Radiator Pressure Adapter. See «Special Tools»(ref-243023-S04058732852006082100000) .
- J 47716 Vac N Fill Coolant Refill Tool. See «Special Tools»(ref-243023-S04058732852006082100000) .
Vac N Fill Procedure
| IMPORTANT | To prevent boiling of the coolant/water mixture in the vehicles cooling system, do not apply vacuum to a cooling system above 49°C (120°F). The tool will not operate properly when the coolant is boiling. |
If a complete engine block drain was required, install the engine block drain plugs. Refer to the appropriate procedure
- «ENGINE BLOCK ASSEMBLE»(ref-243010-S16902653652006082100000) for the 2.4L engine.
- «ENGINE BLOCK ASSEMBLE»(ref-243014-S10426377552006082100000) for the 3.5L engine.
- «ENGINE BLOCK ASSEMBLE»(ref-243015-S18435419192006082100000) for the 3.9L engine.
- Install J-42401-2 into the surge tank fill neck.
- Install J-42401-3 to the surge tank fill neck.
- Attach the Vac N Fill cap to the J-42401-3 .
- Attach the Vac N Fill cap to the vehicles coolant fill port.
- Attach the vacuum gage assembly to the Vac N Fill cap.
- Attach the fill hose to the barb fitting on the vacuum gage assembly. Ensure the valve is closed.
- Pour the coolant mixture into the graduated reservoir.
- Place the fill hose in the graduated reservoir.
- Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
- Attach the venturi assembly to the vacuum tank.
- Attach a shop air hose to the venturi assembly. Ensure the valve on the venturi assembly is closed.
- Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.
- Open the valve on the venturi assembly. The vacuum gage will begin to rise and a hissing noise will be present.
- Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
- To aid in the fill process, position the graduated reservoir above the coolant fill port.
- Slowly open the valve on the vacuum gage assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
- Close the valve on the venturi assembly.
- If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss. If vacuum loss is observed, refer to «Loss of Coolant»(ref-243023-S10524018862006082100000) .
- Open the valve on the vacuum gage assembly. The vacuum gage will drop as coolant is drawn into the system.
- Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 11-17.
- Remove the J-42401-3 from the surge tank fill neck.
- Remove J-42401-2 from the surge tank fill neck.
- Detach the Vac N Fill cap from the vehicles coolant fill port.
- Add coolant to the system as necessary.
- Inspect the concentration of the coolant mixture using J 26568 .
- Detach the vacuum hose from the vacuum gage assembly.
- Attach the extraction hose to the vacuum hose.
- Open the valve on the venturi assembly to start a vacuum draw.
- Use the extraction hose to draw out coolant to the proper level.
- The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.
Radiator Cleaning
| CAUTION | NEVER spray water on a hot radiator. The resulting steam could cause personal injury. |
Note. The radiator 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.
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 43651 Water Pump Holding Tool. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
J 38185 Hose Clamp Pliers. See Special Tools .
Scheme 18
Scheme 19
Scheme 20
Scheme 21
Scheme 22
Scheme 23
Scheme 24
- Drain the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
- Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-242978-S02513727762006082100000) .
- Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-242978-S02513727762006082100000) .
- Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
- Remove the upper radiator support bracket bolts.
- Remove the upper radiator support brackets.
- Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Remove the surge tank outlet hose from the radiator.
- Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Remove the radiator inlet hose from the radiator.
- Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-242990-S25473637352006082100000) .
- Remove the lower radiator air deflector retainers.
- Remove the lower radiator air deflector.
- Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
- Remove the right radiator air deflector retainers.
- Remove the right radiator air deflector.
- Remove the left radiator air deflector retainers.
- Remove the left radiator air deflector.
- Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Remove the radiator outlet hose from the radiator.
- Place a drain pan under the transmission oil cooler pipes.
- Remove the transmission oil cooler pipe attachment nut from the transmission.
- Remove the transmission oil cooler pipes from the transmission.
- Remove the lower radiator support bracket bolts.
- Remove the lower radiator support brackets.
- Remove the radiator lower mounts.
- Remove and discard the condenser mounting bolts from the radiator.
- Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
- Remove and discard the condenser mounting nuts from the radiator.
- Remove the radiator air side seals.
- Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
- Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-243013-S16834146642006082100000) for the 4T40-E/4T45-E automatic transaxle.
- Pry upward on the fan shroud tabs at the radiator clips.
- Remove the cooling fan and shroud assembly.
Scheme 25
- Install the cooling fan and shroud assembly to the radiator.
- Snap the fan shroud tabs into the radiator clips.
- Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-243013-S16834146642006082100000) for the 4T40-E/4T45-E automatic transaxle.
- Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
- Install the radiator air side seals onto the condenser mounting tabs on the radiator.
- Install the condenser mounting nuts to the radiator.
- Insert the condenser mounting tabs into the radiator clips.
- Install the condenser to the radiator bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
- Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
- The radiator air side seals must be in the proper position for proper air flow.
- Install the radiator lower mounts.
- Install the lower radiator support brackets.
- Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
- Install the transmission oil cooler pipes to the transmission.
- Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
- Install the radiator outlet hose to the radiator.
- Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Install the left radiator air deflector.
- Install the left radiator air deflector retainers.
- Install the right radiator air deflector.
- Install the right radiator air deflector retainers.
- Install the right front fender liner. Refer to «Front Fender Liner Replacement»(ref-243002-S03680222752006082100000) .
- Install the lower radiator air deflector.
- Install the lower radiator air deflector retainers.
- Lower the vehicle.
- Install the radiator inlet hose to the radiator.
- Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Install the surge tank outlet hose to the radiator.
- Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(ref-243023-S04058732852006082100000) .
- Remove the rope attached to the condenser and upper tie bar.
- Install the upper radiator support brackets.
- Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
- Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-242978-S02513727762006082100000) .
- Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(ref-242978-S02513727762006082100000) .
- Fill the coolant. Refer to «Draining and Filling Cooling System»(ref-243023-S40090143542006082100000) .
- Inspect the transmission fluid level. Refer to «Transmission Fluid Checking Procedure»(ref-243020-S36429249652006082100000) for the 4T40-E/4T45-E automatic transaxle.
Cooling Fan Control
The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a series/parallel configuration that allows the powertrain control module (PCM) or engine control module (ECM) to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood fuse block. The ground path is provided at G106.
During low speed operation, the PCM or ECM supplies the ground path for the low speed fan relay through the low speed cooling fan relay control circuit. This energizes the cooling fan 1 relay coil, closes the relay contacts and supplies battery positive voltage from the cool fan 1 fuse through the cooling fan motor supply voltage circuit to the left cooling fan. The ground path for the left cooling fan is through the cooling fan S/P relay and the right cooling fan. The result is a series circuit with both fans running at low speed.
During high speed operation the PCM or ECM supplies the ground path for the cooling fan 1 relay through the low speed cooling fan relay control circuit. After a 3 second delay, the PCM or ECM supplies a ground path for the cooling fan 2 relay and the cooling fan S/P relay through the high speed cooling fan relay control circuit. This energizes the cooling fan 2 relay coil, closes the relay contacts and provides a ground path for the left cooling fan. At the same time the cooling fan S/P relay coil is energized closing the relay contacts and provides battery positive voltage from the cool fan 2 fuse on the cooling fan motor supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have their own ground path. The result is a parallel circuit with both fans running at high speed.
The PCM or ECM commands Low Speed Fans ON under the following conditions
- Engine coolant temperature exceeds approximately 106°C (223°F).
- When A/C is requested and the ambient temperature is more than 50°C (122°F).
- A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
- After the vehicle is shut off, if the engine coolant temperature at key-off is more than 140°C (284°F) and system voltage is more than 12 volts. The fans will stay ON for approximately 3 minutes.
The PCM or ECM commands High Speed Fans ON under the following conditions
- Engine coolant temperature reaches 110°C (230°F).
- A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
- When certain DTCs set
Engine Coolant Indicators
TEMP
- The instrument panel cluster (IPC) illuminates the TEMP indicator when the powertrain control module (PCM) or engine control module (ECM) determines that the coolant temperature is more than 128°C (262°F). The IPC receives a discrete input from the PCM or ECM requesting illumination.
- The IPC performs the display test at the start of each ignition cycle. The IPC illuminates the TEMP indicator.
Coolant Level Control
The engine cooling system contains an engine coolant level switch to alert the driver in the event of a low coolant level. When the engine coolant level in the surge tank falls below a certain level, the coolant level switch opens. When the body control module (BCM) detects an open or a high voltage level on the coolant level indicator control circuit, for at least 10 seconds, it will send a GM LAN message to the driver information center (DIC) requesting display of the low coolant level message. There is approximately a 10-second delay before the BCM sends the GM LAN message to prevent the message from being displayed, due to coolant sloshing in the surge tank.
Coolant Heater
The optional engine coolant heater (RPO K05) operates using AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather -29°C (-20°F). The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug when not in use.
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.
Cooling Cycle
Coolant flows from the radiator outlet and into the water pump inlet. Some coolant flows from the water pump, to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost capability as the coolant warms up.
Coolant also flows from the water pump outlet and into the engine block. In the engine block, the coolant circulates through the water jackets surrounding the cylinders where the coolant absorbs heat.
The coolant then flows through the cylinder head gasket openings and into the cylinder heads. In the cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where the coolant absorbs additional heat.
Coolant is also directed to the throttle body. There the coolant circulates through passages in the casting. During initial start up, the coolant assists in warming the throttle body.
From the cylinder heads, the coolant flows to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine reaches normal operating temperature or the coolant will flow through the thermostat and into the radiator where the coolant is cooled. At this point, the coolant flow cycle is completed.
Efficient operation of the cooling system requires proper functioning of all cooling system components. The cooling system consists of the following 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 consisting of a core and 2 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 left hand tank. The drain cock unit includes the drain cock and drain cock seal.
Heat is removed from the coolant as the coolant passes through the radiator. The fins on the core transfer heat from the coolant passing through the tubes. Air passing between the fins absorbs the heat and cools the coolant.
Pressure Cap
The pressure cap seals and pressurizes the cooling system. The cap contains a blow off or pressure valve and a vacuum or an atmospheric valve
- The pressure valve is held against the seat by a spring that protects the radiator by relieving pressure that exceeds 15 psi.
- The vacuum valve is held against the seat by a spring that permits opening of the valve to relieve vacuum created when the cooling system cools. The vacuum, if not relieved, might cause the radiator to collapse.
The pressure cap allows the cooling system pressure to build up when the temperature increases. As the pressure builds, the boiling point of the coolant increases. Therefore, the 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 becomes, the faster the heat transfers from the radiator into the cooler air.
The pressure in the cooling system can get too high. When the pressure exceeds the strength of the spring, the pressure valve rises, venting the excess pressure.
As the engine cools, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open. This equalizes the pressure in the cooling system with the atmospheric pressure, preventing the radiator from collapsing.
Coolant Recovery System
The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The recovery reservoir is also called a recovery tank or expansion tank. This tank is partially filled with coolant and is connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator and the reservoir.
In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure within the cooling system gets too high, the pressure valve in the pressure cap will open. This allows the coolant, which has expanded due to heat, to flow through the overflow tube and into the recovery reservoir. As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum opens the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be siphoned back into the radiator. Under normal operating conditions, no coolant is lost. Although the coolant level in the recovery reservoir goes up and down, the radiator and cooling system are kept full. An advantage to using a coolant recovery reservoir is the elimination of almost all air bubbles from 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 a flat plate mounted on the pump shaft with a series of flat or curved blades or vanes. 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, which never need to be lubricated. With a sealed bearing, grease cannot leak out and dirt and water cannot get in.
The water pump circulates coolant throughout the cooling system. The pump is driven by the crankshaft from the drive belt.
Thermostat
The thermostat is a coolant flow control component, whose purpose is to regulate the operating temperature of the engine. The thermostat utilizes a temperature sensitive wax-pellet element, which connects to a valve through a piston. Heating causing the element to expand and exert pressure against a rubber diaphragm. This pressure forces the valve to open. Cooling causes the element to contract. This contraction allows a spring to push the valve closed.
When the coolant temperature is below 91°C (195°F), the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up quickly. After the coolant temperature reaches 91°C (195°F), 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, even after opening. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.
Transmission Oil Cooler
The transmission oil cooler is a heat exchanger and is located inside the right side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant that surrounds the oil cooler as the transmission fluid passes through the cooler.
The transmission oil pump circulates the fluid through the feed line to the oil cooler. The fluid then flows through the cooler while the engine coolant absorbs heat from the fluid. The fluid is then pumped through the return line to the transmission.