Engine Cooling System: Diagnosis Saturn Astra I

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

Diagnostic Starting Point - Engine Cooling

Begin the system diagnosis with the diagnostic system check. Refer to Diagnostic System Check - Vehicle . The Diagnostic System Check - Vehicle will provide the following information

1. The identification of the control modules which command the system
2. The ability of the control modules to communicate through the serial data circuits
3. The identification of any stored DTCs and their status

The use of the Diagnostic System Check - Vehicle will identify the correct procedure for diagnosing the system and where the procedure is located.

Diagnostic Instructions

1. Perform the «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(ref-302315-S32068625472008102100000) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(ref-302315-S09719072712008102100000) provides an overview of each diagnostic category.

Diagnostic Fault Information

Conditions for Running the DTCs

1. DTC P0606 is not set.
2. The system voltage is more than 9 volts.
3. The engine is running.

Action Taken When the DTC Sets

DTCs P0691, P0692, P0693 and P0694 are Type B DTCs.

Conditions for Clearing the DTC

DTCs P0691, P0692, P0693 and P0694 are Type B DTCs.

Circuit/System Testing

1. Ignition OFF, disconnect the affected relay.
2. Ignition ON, connect a test lamp between the positive terminal at the battery and the relay control circuit terminal 86.
3. Command the relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the relay control circuit for a short to ground. If the circuit tests normal, replace the ECM. If the test lamp is always OFF, test the relay control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.
4. Connect a 20A fused jumper wire between the positive voltage terminal at the battery and the fan voltage supply circuit terminal 87 and verify fan activation. If the fan does not activate, test the fan voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the fan.
5. Ignition ON, connect a 20A fused jumper wire between the relay switch voltage supply circuit terminal 30 and the fan voltage supply circuit terminal 87 and verify fan activation. If the fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, replace the relay.
6. Ignition ON, verify that a test lamp illuminates between the relay coil voltage supply circuit terminal 85 and ground. If the test lamp does not illuminate, test the relay coil voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, replace the relay.
7. If all circuits and the ECM test normal, replace the affected relay.

1. Perform the «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(ref-302315-S32068625472008102100000) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(ref-302315-S09719072712008102100000) provides an overview of each diagnostic category.

Conditions for Running the DTC

1. The engine is running.
2. The system voltage is more than 9 volts.
3. DTC P0606 is not set.

DTCs P0691, P0692, P0693 and P0694 are Type B DTCs.

DTCs P0691, P0692, P0693 and P0694 are Type B DTCs.

1. Ignition OFF, disconnect the appropriate relay.
2. Ignition ON, verify that a test lamp does not illuminate between the control circuit terminal 87 and ground. If the test lamp illuminates, test the control circuit for a short to voltage.
3. Verify that a test lamp illuminates between the ignition circuit terminal 30 and ground. If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, test the control circuit terminal 87 for a short to ground. If the circuit tests normal, test or replace the appropriate relay.
4. Verify that a test lamp illuminates between the ignition circuit terminal 30 and ground. If the test lamp does not illuminate, test the ignition circuit for an open/high resistance.
5. Disconnect the harness connector at the cooling fan.
6. Test for less than 1 ohm between the cooling fan ground circuit terminal 1 and ground. If greater than the specified range, test the ground circuit for an open/high resistance.
7. Connect the harness connector at the cooling fan.
8. Connect a 20A fused jumper wire between the ignition circuit terminal 30 and the control circuit terminal 87. Verify the cooling fan is activated. If the cooling fan does not activate, test the control circuit for an open/high resistance. If the circuit tests normal, test or replace the cooling fan.
9. Connect a test lamp between the ignition circuit terminal 30 and the control circuit terminal 85.
10. Clear the DTCs with a scan tool.
11. Command the appropriate relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.
12. If all circuits test normal, test or replace the appropriate relay.

Relay Test

1. Ignition OFF, disconnect the appropriate relay.
2. Test for 75-90 ohms between terminals 85 and 86. If the resistance is not within the specified range, replace the relay.
3. Test for infinite resistance between the following terminals: 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified value, replace the relay.
4. Test for less than 1 ohm between terminals 30 and 87A. If greater than the specified range, replace the relay.
5. Install a 5A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm between terminals 30 and 87. If greater than the specified range, replace the relay.

Important Preliminary Inspections Before Starting

Before using the Symptom diagnosis, perform the following

1. Perform «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) and verify all of the following items: Ensure that the engine control module (ECM) and indicator lamp are operating correctly. Ensure that there are no diagnostic trouble codes (DTCs) that are stored. Scan tool data is within a normal operating range.
2. Verify the customer concern.
3. Perform the Visual/Physical Inspection in this section. The visual/physical inspection is extremely important, and can lead to correcting a condition without additional testing. It may also help reveal the cause of an intermittent condition.
4. Locate the correct symptom. Perform the tests and inspections associated with the symptom.

Review the system operation in order to familiarize yourself with the system functions.

Visual/Physical Inspection

Note. Use the connector test adapter kit J 35616-A for any test that requires probing the following items: The PCM harness connectors The electrical center fuse/relay cavities The component terminals The component harness connector Using this kit will prevent damage caused by the improper probing of connector terminals.

Several of the symptom procedures call for a careful visual and physical inspection. This can lead to correcting a condition without further tests and can save time. This inspection should include the following areas

1. Ensure that the ECM grounds are clean, tight, and correctly located.
2. Inspect cooling system hoses and pipes for splits, kinks, and proper connections. Inspect thoroughly for any type of a leak or a restriction.
3. Inspect for a dirty or restricted radiator and HVAC condenser.
4. Inspect for aftermarket devices which could affect the operation of the Cooling System.
5. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
6. Inspect the surge tank reservoir for the proper coolant level.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Cooling Fan Always On (Duel Fan)»(ref-302344-S30609946182008102100000) or «Cooling Fan Always On (Single Fan)»(ref-302344-S09159249002008102100000)
2. «Cooling Fan Inoperative (Duel Fan)»(ref-302344-S30336916752008102100000) or «Cooling Fan Inoperative (Single Fan)»(ref-302344-S26816043022008102100000)
3. «Engine Overheating»(ref-302344-S39304540602008102100000)
4. «Loss of Coolant»(ref-302344-S24227198852008102100000)
5. «Thermostat Diagnosis»(ref-302344-S03743558312008102100000)
6. «Engine Fails To Reach Normal Operating Temperature»(ref-302344-S08673231162008102100000)

1. Perform the «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(ref-302315-S32068625472008102100000) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(ref-302315-S09719072712008102100000) provides an overview of each diagnostic category.

1. Ignition OFF, disconnect the relays.
2. Ignition ON, observe that the fans are not activated. If the fans are not activated, replace the faulty relay. If a fan is activated, test the fan voltage supply circuits for a short to voltage.

1. Perform the «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(ref-302315-S32068625472008102100000) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(ref-302315-S09719072712008102100000) provides an overview of each diagnostic category.

1. Ignition OFF, disconnect the appropriate relay.
2. Ignition ON, verify that a test lamp does not illuminate between the control circuit terminal 87 and ground. If the test lamp illuminates, test the control circuit for a short to voltage.
3. Verify that a test lamp illuminates between the ignition circuit terminal 30 and ground. If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, test the control circuit terminal 87 for a short to ground. If the circuit tests normal, test or replace the appropriate relay.
4. Verify that a test lamp illuminates between the ignition circuit terminal 30 and ground. If the test lamp does not illuminate, test the ignition circuit for an open/high resistance.
5. Disconnect the harness connector at the cooling fan.
6. Test for less than 1 ohm between the cooling fan ground circuit terminal 1 and ground. If greater than the specified range, test the ground circuit for an open/high resistance.
7. Connect the harness connector at the cooling fan.
8. Connect a 20A fused jumper wire between the ignition circuit terminal 30 and the control circuit terminal 87. Verify the cooling fan is activated. If the cooling fan does not activate, test the control circuit for an open/high resistance. If the circuit tests normal, test or replace the cooling fan.
9. Connect a test lamp between the ignition circuit terminal 30 and the control circuit terminal 85.
10. Clear the DTCs with a scan tool.
11. Command the appropriate relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.
12. If all circuits test normal, test or replace the appropriate relay.

1. Ignition OFF, disconnect the appropriate relay.
2. Test for 75-90 ohms between terminals 85 and 86. If the resistance is not within the specified range, replace the relay.
3. Test for infinite resistance between the following terminals: 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified value, replace the relay.
4. Test for less than 1 ohm between terminals 30 and 87A. If greater than the specified range, replace the relay.
5. Install a 5A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm between terminals 30 and 87. If greater than the specified range, replace the relay.

1. Perform the «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(ref-302315-S32068625472008102100000) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(ref-302315-S09719072712008102100000) provides an overview of each diagnostic category.

1. Ignition OFF, disconnect both relays.
2. One at a time, connect a 20A fused jumper wire between the positive voltage terminal at the battery and each fan voltage supply circuit terminal 87 and verify fan activation. If the fan does not activate, test the fan voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal, test the fan ground circuit for an open/high resistance. If the fan did not activate and the circuits test normal, replace the fan.
3. Ignition ON, one at a time, connect a 20A fused jumper wire between the relay switch voltage supply circuit terminal 30 and the fan voltage supply circuit terminal 87 and verify fan activation. If a fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and it's fuse is open, test all connected components and replace as necessary.
4. If the fans and all circuits test normal, replace the relay.

1. Perform the «Diagnostic System Check - Vehicle»(ref-302315-S22962940552008102100000) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(ref-302315-S32068625472008102100000) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(ref-302315-S09719072712008102100000) provides an overview of each diagnostic category.

1. Ignition OFF, disconnect the appropriate relay.
2. Ignition ON, verify that a test lamp does not illuminate between the control circuit terminal 87 and ground. If the test lamp illuminates, test the control circuit for a short to voltage.
3. Verify that a test lamp illuminates between the ignition circuit terminal 30 and ground. If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, test the control circuit terminal 87 for a short to ground. If the circuit tests normal, test or replace the appropriate relay.
4. Verify that a test lamp illuminates between the ignition circuit terminal 30 and ground. If the test lamp does not illuminate, test the ignition circuit for an open/high resistance.
5. Disconnect the harness connector at the cooling fan.
6. Test for less than 1 ohm between the cooling fan ground circuit terminal 1 and ground. If greater than the specified range, test the ground circuit for an open/high resistance.
7. Connect the harness connector at the cooling fan.
8. Connect a 20A fused jumper wire between the ignition circuit terminal 30 and the control circuit terminal 87. Verify the cooling fan is activated. If the cooling fan does not activate, test the control circuit for an open/high resistance. If the circuit tests normal, test or replace the cooling fan.
9. Connect a test lamp between the ignition circuit terminal 30 and the control circuit terminal 85.
10. Clear the DTCs with a scan tool.
11. Command the appropriate relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.
12. If all circuits test normal, test or replace the appropriate relay.

1. Ignition OFF, disconnect the appropriate relay.
2. Test for 75-90 ohms between terminals 85 and 86. If the resistance is not within the specified range, replace the relay.
3. Test for infinite resistance between the following terminals: 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified value, replace the relay.
4. Test for less than 1 ohm between terminals 30 and 87A. If greater than the specified range, replace the relay.
5. Install a 5A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm between terminals 30 and 87. If greater than the specified range, replace the relay.

Thermostat Diagnosis

Pressure Cap Testing

Special Tools

1. J 24460-01 Cooling System Pressure Tester
2. J 42401 Radiator Cap/Surge Tank Test Adapter

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use J 24460-01 (1) with J 42401 (2) in order to test the radiator cap.
4. Test the pressure cap for the following conditions: Pressure the release when J 24460-01 exceeds the pressure rating of the pressure cap. Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions: The pressure cap does not release the pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

Cooling System Leak Testing

Special Tools

1. KM-471 Adapter. See «Special Tools»(ref-302344-S04730840612008102100000) .
2. KM-6327 Cooling System Test Adapter. See «Special Tools»(ref-302344-S04730840612008102100000) .

1. Open the hood.
2. Detach the coolant expansion tank closure cap.
3. Check the coolant level. Top up the coolant to the COLD mark if necessary.
4. Pull the coolant expansion tank from the bracket in the direction of the battery.
5. Attach the coolant system tester (1) with KM-471 (2) and KM-6327 (3) to the coolant expansion tank. See «Special Tools»(ref-302344-S04730840612008102100000) .
6. Apply approximately 100 kPa (15 psi) to the cooling system.
7. Cooling system, check for leaks
8. Detach the cooling system tester. Release the pressure. Detach the cooling system tester with KM-471 . See «Special Tools»(ref-302344-S04730840612008102100000) .
9. Attach the coolant expansion tank closure cap.
10. Slide the coolant expansion tank onto the bracket.
11. Close the hood.