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.
Low Engine Coolant Indicator Always On
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics (2.2L) or Engine Cooling Schematics (2.0L) Connector End View Reference: Cooling System Connector End Views DEFINITION: The low coolant indicator 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 | Turn the ignition ON, with the engine OFF. With a scan tool command the instrument cluster indicators ON and OFF. Does the low coolant indicator lamp turn ON and OFF with each command? | Go to Step 3 | Go to Step 5 |
| 3 | Disconnect the coolant level switch connector. Does the low coolant indicator turn OFF? | Go to Step 6 | Go to Step 4 |
| 4 | Test the signal circuit of the coolant level switch for a short to voltage. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you find and correct the condition? | Go to Step 11 | Go to Step 7 |
| 5 | Inspect for poor connections at the harness connector of the instrument panel cluster (IPC). 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 11 | Go to Step 8 |
| 6 | Inspect for poor connections at the harness connector of the coolant level switch. 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 11 | Go to Step 9 |
| 7 | Inspect for poor connections at the harness connector of the body control module (BCM). 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 11 | Go to Step 10 |
| 8 | Replace the IPC. Refer to Instrument Panel Cluster (IPC) Replacement in Instrument Panel, Gages, and Console. Did you complete the repair? | Go to Step 11 | |
| 9 | Replace the coolant level switch. Refer to Surge Tank Replacement . Did you complete the replacement? | Go to Step 11 | |
| 10 | 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 11 | |
| 11 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
Low Engine Coolant Indicator Always On
Cooling Fan Always On (2.2L (L61))
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics (2.2L) or Engine Cooling Schematics (2.0L) Connector End View Reference: Cooling System Connector End Views DEFINITION: The engine cooling fan motor runs continuously. | |||
| 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. Is the engine cooling fan running all the time? | Go to Step 3 | Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems |
| 3 | Remove the cooling fan relay. Did the cooling fan turn OFF? | Go to Step 5 | Go to Step 4 |
| 4 | Repair the short to B+ in the cooling fan motor supply voltage circuit. Refer to Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 7 | |
| 5 | Inspect for poor connections at the cooling fan 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 7 | Go to Step 6 |
| 6 | Replace the cooling fan relay. Did you complete the repair? | Go to Step 7 | |
| 7 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
Cooling Fan Always On (2.2L (L61))
Cooling Fan Always On (2.0L (LSJ))
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics (2.2L) or Engine Cooling Schematics (2.0L) Connector End View Reference: Cooling System Connector End Views DEFINITION: One or both engine cooling fan motors run 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 cooling 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. Did you find and correct the condition? | Go to Step 18 | Go to Step 14 |
| 6 | Remove the cool fan 3 relay. Did the right cooling fan turn OFF? | Go to Step 10 | Go to Step 8 |
| 7 | Remove the cool fan 1 relay. Did the cooling fans turn OFF? | Go to Step 12 | Go to Step 9 |
| 8 | Remove the cool fan S/P 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 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 S/P 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 S/P 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 (2.0L (LSJ))
Cooling Fan Inoperative (2.2L (L61))
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics (2.2L) or Engine Cooling Schematics (2.0L) Connector End View Reference: Cooling System Connector End Views DEFINITION: The engine cooling fan motor does not operate. | |||
| 1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle in Vehicle DTC Information |
| 2 | Install a scan tool. Turn ON the ignition, with the engine OFF. With a scan tool, command the cooling fan ON and OFF. Does the engine cooling fan turn ON and OFF with each command? | Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems | Go to Step 3 |
| 3 | Turn OFF the ignition. Remove the cooling fan relay. Probe the battery positive voltage circuit of the cooling fan relay switch side with a test lamp that is connected to a good ground. Does the test lamp illuminate? | Go to Step 4 | Go to Step 7 |
| 4 | Connect a 20-amp fused jumper wire between the battery positive voltage circuit of the cooling fan relay and the cooling fan motor supply voltage circuit of the cooling fan relay. Does the cooling fan operate? | Go to Step 10 | Go to Step 5 |
| 5 | Disconnect the cooling fan connector. Probe the cooling fan motor supply voltage circuit at the harness connector with a test lamp that is connected to a good ground. Does the test lamp illuminate? | Go to Step 6 | Go to Step 8 |
| 6 | Probe the harness connector of the cooling fan motor with a test lamp connected between the cooling fan motor supply voltage circuit and the ground circuit of the cooling fan motor. Does the test lamp illuminate? | Go to Step 11 | Go to Step 9 |
| 7 | Repair the battery positive circuit of the cooling fan relay. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 14 | |
| 8 | Repair the supply voltage circuit of the cooling fan motor. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 14 | |
| 9 | Repair the ground circuit of the cooling fan motor. Refer to Circuit Testing and Wiring Repairs in Wiring Systems. Did you complete the repair? | Go to Step 14 | |
| 10 | Inspect for poor connections at the cooling fan 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 14 | Go to Step 12 |
| 11 | Inspect for poor connections at the harness connector of the cooling fan motor. 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 14 | Go to Step 13 |
| 12 | Replace the cooling fan relay. Did you complete the repair? | Go to Step 14 | |
| 13 | Replace the cooling fan motor. Refer to Cooling Fan and Shroud Replacement (2.2L (L61)) or Cooling Fan and Shroud Replacement (2.0L (LSJ)) . Did you complete the repair? | Go to Step 14 | |
| 14 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2 |
Cooling Fan Inoperative (2.2L (L61))
Cooling Fan Inoperative (2.0L (LSJ))
| Step | Action | Yes | No |
|---|---|---|---|
| Schematic Reference: Engine Cooling Schematics (2.2L) or Engine Cooling Schematics (2.0L) 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 in Vehicle DTC Information |
| 2 | Install a scan tool. Turn ON the engine. With a scan tool, monitor the engine coolant temperature (ECT) in the Inputs/Outputs scan tool data. Bring the vehicle up to normal operating temperature. At 106°C (223°F) the low speed engine cooling fans should engage. Do the low speed engine cooling fans engage? | Go to Step 3 | Go to Step 4 |
| 3 | IMPORTANT: A 3 second delay occurs before the powertrain control module (PCM) changes the cooling fan speed. With a scan tool, monitor the ECT in the Inputs/Outputs scan tool data. At 110°C (230°F) the high speed engine cooling fans should engage. Do the high speed engine cooling fans engage? | Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems | 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 in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 and Wiring Repairs in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 in Wiring Systems. 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 (2.2L (L61)) or Cooling Fan and Shroud Replacement (2.0L (LSJ)) . Did you complete the replacement? | Go to Step 25 | |
| 24 | Replace the right cooling fan. Refer to Cooling Fan and Shroud Replacement (2.2L (L61)) or Cooling Fan and Shroud Replacement (2.0L (LSJ)) . 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) 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 (2.0L (LSJ))
Engine Overheating
| Step | Action | Value(s) | Yes | No |
|---|---|---|---|---|
| DEFINITION: The engine temperature lamp comes ON and stays ON, or the 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 Draining and Filling Cooling System (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) . 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. Refer to Radiator Air Baffle and Deflector Replacement - Side (2.2L (L61)) or Radiator Air Baffle and Deflector Replacement - Side (2.0L (LSJ)) or Radiator Air Baffle and Deflector Replacement - Upper . 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 (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) . 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 engine coolant temperature sensor faulty? | Go to Step 12 | Go to Step 13 | |
| 12 | Replace the ECT. Refer to Engine Coolant Temperature (ECT) Sensor Replacement in Engine Controls - 2.2L (L61). Does the engine still overheat? | Go to Step 13 | System OK | |
| 13 | Check the radiator for any airflow 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 airflow 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 Draining and Filling Cooling System (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) . 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 (2.2L (L61)) or Cooling Fan and Shroud Replacement (2.0L (LSJ)) . 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 . 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 (2.2L - L61) . 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 loosing 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 in Engine Cooling |
| 2 | Repair any present DTCs. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information. 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 (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) . 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 coolant recovery system. Does the coolant recovery system discharge coolant while the engine is idling? | Go to Step 15 | Go to Step 11 |
| 11 | Visually inspect the hoses, pipes and hose clamps at the following locations: The coolant surge tank The heater core The radiator Are any of the hoses, clamps or pipes leaking? | Go to Step 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 (2.2L (L61)) or Cooling System Leak Testing (2.0L (LSJ)) . 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 a milky substance 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 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 in Heating, Ventilation and Air Conditioning. Is the repair complete? | Go to Step 31 | |
| 23 | Remove the transmission oil cooler lines from the radiator. Pressure test the cooling system. Refer to Cooling System Leak Testing (2.2L (L61)) or Cooling System Leak Testing (2.0L (LSJ)) . 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 . Service the automatic transmission. Refer to Engine Coolant/Water in Transmission in Automatic Tranaxle-4T40-E/4T45-E. 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 Engine Will Not Crank - Crankshaft Will Not Rotate in Engine Mechanical-2.2L (L61). 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 Coolant in Combustion Chamber or Coolant in Engine Oil in Engine Mechanical-2.2L (L61). Is the repair complete? | Go to Step 31 | |
| 29 | Repair the engine knock. Refer to Lower Engine Noise, Regardless of Engine Speed in Engine Mechanical-2.2L (L61). Is the repair complete? | Go to Step 31 | |
| 30 | Repair the combustion pressure in the cooling system problem. Refer to Coolant in Combustion Chamber in Engine Mechanical-2.2L (L61). 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 |
|---|---|---|---|
| 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 (2.2L (L61)) . Did you complete the repair? | 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 (2.2L (L61)) . Did you complete the repair? | 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 (2.2L (L61)) or Draining and Filling Cooling System (2.0L (LSJ)) . 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 Thermostat Replacement . Does the engine still fail to reach normal operating temperature? | System OK |
Engine Fails To Reach Normal Operating Temperature
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 «Capacities - Approximate Fluid»(ref-197013-S27599306632005101000000) in General Information.
- Install surge tank 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.
- Inspect the cooling system for leaks.
- 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 (1) if the plug was removed during the draining process. Tighten: Tighten the plug to 22 N.m (16 lb in).
- Lower the vehicle.
- Remove the upper radiator inlet hose from the passenger side radiator.
- Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the engine through the upper radiator hose.
- Install the upper radiator inlet hose to the radiator.
- Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system until the coolant reaches and maintains a level slightly above the cold fill line on the surge tank. Refer to «Capacities - Approximate Fluid»(ref-197013-S27599306632005101000000) in General Information.
- Install surge tank 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.
- Inspect the cooling system for leaks.
- Rinse away any excess coolant from the engine and the engine compartment.
Tools Required
GE-47622 Hose Clamp Pliers
- Install the inlet hose to the auxiliary water pump.
- Using GE-47622 , reposition the inlet hose clamp to secure the hose.
- Lower the vehicle.
- Remove the right front headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb Replacement»(ref-196945-S22366714082005101000000) in Lighting Systems.
- Remove the bleeder screw from the radiator on the passenger top side of the charge air cooler.
- Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean, drinkable water to the cooling system until the coolant level reaches the top of the bleeder screw opening. Refer to «Capacities - Approximate Fluid»(ref-197013-S27599306632005101000000) in Maintenance and Lubrication.
- Install the bleeder screw.
- Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean, drinkable water to the cooling system until the coolant level is just visible in the bottom of the charge air cooler reservoir. The coolant level will reach the hot fill line once the system has reached operating temperature.
- Install the cap to the charge air cooler reservoir.
- Inspect the cooling system for leaks.
- Install the right front headlamp assembly. Refer to «Headlamp Assembly or Headlamp Bulb Replacement»(ref-196945-S22366714082005101000000) in Lighting Systems.
- Rinse away any excess coolant from the engine and the engine compartment.
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.
SA9111E Hose Clamp Pliers. See Special Tools .
GE-47622 Hose Clamp Pliers
SA9111E Hose Clamp Pliers. See Special Tools .
SA9111E Hose Clamp Pliers. See Special Tools .
SA9111E Hose Clamp Pliers. See Special Tools .
SA9111E Hose Clamp Pliers. See Special Tools .
SA9111E Constant Force Clamp Pliers. See Special Tools .
GE-47622 Hose Clamp Pliers
- SA9111E Hose Clamp Pliers. See «Special Tools»(ref-196980-S01424700812005101000000) .
- GE-47622 Hose Clamp Pliers
GE-47622 Hose Clamp Pliers
GE-47622 Hose Clamp Pliers
SA9111E Hose Clamp Pliers. See Special Tools .
J 43651 Water Pump Holding Tool. See Special Tools .
GE-47622 Hose Clamp Pliers
SA9111E Hose Clamp Pliers. See Special Tools .
SA9111E Hose Clamp Pliers. See Special Tools .
Cooling Fan Control 2.2L (L61)
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 cooling fan relay through the cooling fan relay control circuit. This energizes the cooling fan relay coil, closes the relay contacts, and supplies battery positive voltage from the cooling 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.
The ECM commands the fan on under the following conditions
- Engine coolant temperature exceeds approximately 106°C (223°F).
- A/C refrigerant pressure exceeds 1310 kPa (190 psi).
- A/C is requested and vehicle speed is below 100 km/h (62 mph) with A/C pressure above 1413 kPa (205 psi).
- AF23-5 Transmission fluid temperature exceeds 130°C (266°F).
- VT25-E Transmission fluid temperature exceeds 140°C (284°F).
- When the engine coolant temperature exceeds 100°C (212°F) at key off, the fan will run for up to 108 seconds.
The ECM commands the fan off under the following conditions
- Engine coolant temperature drops below approximately 100°C (212°F).
- Throttle position is greater than 95%.
- Vehicle speed exceeds 113 km/h (70 mph)
Cooling Fan Control 2.0L (LSJ)
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) to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood junction block. The ground path is provided at G105.
During low speed operation, the PCM 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 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 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 s/p relay coil, closes the relay contacts, and provides a ground path for the left cooling fan. At the same time the cooling fan 2 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 commands Low Speed Fans on under the following conditions
- Engine coolant temperature exceeds approximately 106°C (223°F).
- A/C refrigerant pressure exceeds 1310 kPa (190 psi).
- After the vehicle is shut off if the engine coolant temperature 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
- Engine coolant temperature reaches 110°C (230°F).
- A/C refrigerant pressure exceeds 1655 kPa (240 psi).
- When certain DTCs set.
LOW COOLANT LEVEL
The IPC illuminates the low coolant warning indicator when any of the following occur
- The 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.
Coolant Heater
The optional engine coolant heater (RPO K05) operates using 110-volt 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 it 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 it absorbs additional heat.
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 it will flow through the thermostat and into the radiator where it 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. 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.
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.