Engine Cooling System: Other Saturn VUE I

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

Low Engine Coolant Indicator Always On

Cooling Fan Always On (L61)

Cooling Fan Always On (L61)

Cooling Fan Always On (L66)

Cooling Fan Always On (L66)

Cooling Fan Inoperative (L61)

Cooling Fan Inoperative (L61)

Cooling Fan Inoperative (L66)

Cooling Fan Inoperative (L66)

Engine Overheating

Engine Overheating

Loss of Coolant

Loss of Coolant

Coolant Heater Inoperative

Coolant Heater Inoperative

Engine Fails To Reach Normal Operating Temperature

1. Verify that the cooling system is properly filled. Refer to «Draining and Filling Cooling System»(ref-188798-S18526938392005090200000) .
2. If the complaint is a low temperature gauge reading, check the temperature gage for proper operation. Connect a scan tool to the vehicle and read the system temperature. Compare this reading to the temperature gauge. Replace the gauge or switch if necessary.
3. Refer to «Heating Performance Diagnostic»(ref-188838-S37122400422005090200000) in Heating, Ventilation, and Air Conditioning if the complaint is no heat from the HVAC system.
4. Verify proper thermostat operation. Refer to «Thermostat Diagnosis»(ref-188798-S16574484012005090200000) .

Tools Required

1. SA9141E Cooling System Pressure Test Kit. See «Special Tools and Equipment»(ref-188798-S26468822222005090200000) .
2. J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools and Equipment»(ref-188798-S26468822222005090200000) .

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use the SA9141E (1) with J 42401 (2) in order to test the pressure cap. See «Special Tools and Equipment»(ref-188798-S26468822222005090200000) .
4. Test the pressure cap for the following conditions: Pressure release when the SA9141E exceeds the pressure rating of the pressure cap. See «Special Tools and Equipment»(ref-188798-S26468822222005090200000) . 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 pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

Filling Procedure

1. Slowly add a mixture of 50/50 DEX-COOL antifreeze and clean water to the coolant surge tank. Fill the cooling system as indicated below: For L61 vehicles when the engine block is not drained, add 3.5 liters (3.7 qts) For L61 vehicles when the engine block is drained, add 6 liters (6.3 qts) For L66 vehicles, add 5 liters (5.3 qts)
2. Start the engine and check for leaks.
3. Run the engine and cycle the vehicle from idle to 3,000 RPM in 30 second intervals until the engine cooling fan comes ON, the engine cooling fan turns ON at approximately 102°C (216°F). Repeat this process twice before the engine is turned OFF.
4. Return the engine to idle, and idle for 30 seconds, then turn the engine OFF.
5. Allow the vehicle to cool, before adding additional coolant.
6. Add additional coolant to the surge tank until the level is approximately 13 mm (0.5 in) above the surge tank seam.
7. Install the coolant surge tank cap.

J 43651 Water Pump Holding Tool. See Special Tools and Equipment .

Cooling Fan Control

The engine cooling fan system consists of one cooling fan and two relays with the L61 4 cylinder engine and two cooling fans and three relays with the L66 V6 engine. The relays are powered by the battery positive voltage circuit and controlled by a switched ground from the engine control module (ECM) or powertrain control module (PCM).

During operation, the ECM/PCM supplies the ground path for the cooling fan relays 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/PCM commands the fan on under the following conditions

1. Engine coolant temperature exceeds approximately 114°C (237°F) - L61/2.2L.
2. Engine coolant temperature exceeds approximately 98°C (208°F) Low Fan Speed - L66/3.5L.
3. Engine coolant temperature exceeds approximately 102°C (216°F) High Fan Speed - L66/3.5L.
4. A/C refrigerant pressure exceeds 2,945 kPa (427 psi) - L61/2.2L.
5. A/C refrigerant pressure exceeds 361 kPa (52 psi) Low Fan Speed - L66/3.5L.
6. A/C refrigerant pressure exceeds 2100 kPa (300 psi) High Fan Speed - L66/3.5L.
7. With the L66 V6 engine, when the engine coolant temperature exceeds 112°C (234°F) at key off, the fan high speed will run for up to 300 seconds. If within that time frame 102°C (216°F) is reached then fan speed will change from high to low speed. If within that time frame 99°C (210°F) is reached then fan speed will change from low to off.

The ECM/PCM commands the fan off under the following conditions

1. A/C is requested and engine speed exceeds 6,250 RPM - L61/2.2L.
2. A/C is requested and engine speed exceeds 6,240 RPM - L66/3.5L.
3. Engine coolant temperature exceeds approximately 99°C (210°F) turns the cooling fans from low to off - L66/3.5L

LOW COOLANT LEVEL

The IPC illuminates the low coolant warning indicator when any of the following occur

1. 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.
2. 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.