Ford Escape Manuals
Ford Escape 2020-2024 Service Manual / Powertrain / Engine / Engine Cooling / Diagnosis and Testing - Engine Cooling

Ford Escape: Engine Cooling / Diagnosis and Testing - Engine Cooling


Special Tool(s)

Coolant/Battery Refractometer
ROB75240 or equivalent
D-Gas Adapter
300-OTC014-R1068 or equivalent
Radiator Tester
014-R1072 or equivalent
UView® Combustion Leak Tester
UVU560000-R

Diagnostic Trouble Code (DTC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Module DTC Description Action
PCM P0125:00 Insufficient Coolant Temp For Closed Loop Fuel Control: No Sub Type Information GO to Pinpoint Test C
PCM P0128:00 Coolant Thermostat (Coolant Temp Below Thermostat Regulating Temperature): No Sub Type Information GO to Pinpoint Test C
PCM P01E4:00 Engine Coolant Temperature Sensor 3 Circuit Range/Performance: No Sub Type Information GO to Pinpoint Test F
PCM P01E5:00 Engine Coolant Temperature Sensor 3 Circuit Low: No Sub Type Information GO to Pinpoint Test F
PCM P01E6:00 Engine Coolant Temperature Sensor 3 Circuit High: No Sub Type Information GO to Pinpoint Test F
PCM P0217:00 Engine Coolant Overtemperature Condition: No Sub Type Information GO to Pinpoint Test B
PCM P1299:00 Cylinder Head Overtemperature Protection Active: No Sub Type Information GO to Pinpoint Test B
PCM P237C:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Circuit/Open: No Sub Type Information GO to Pinpoint Test D
PCM P237D:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Circuit Low: No Sub Type Information GO to Pinpoint Test D
PCM P237E:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Circuit High: No Sub Type Information GO to Pinpoint Test D
PCM P237F:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Performance: No Sub Type Information GO to Pinpoint Test D
PCM P26CA:00 Engine Coolant Pump Control Circuit/Open: No Sub Type Information GO to Pinpoint Test E
PCM P26CB:00 Engine Coolant Pump Performance/Stuck Off: No Sub Type Information GO to Pinpoint Test E
PCM P26CE:00 Engine Coolant Pump Overspeed/Air In System: No Sub Type Information GO to Pinpoint Test A
PCM P26D0:00 Engine Coolant Pump Control Module System Voltage Low: No Sub Type Information GO to Pinpoint Test E
PCM P26D1:00 Engine Coolant Pump Control Module System Voltage High: No Sub Type Information GO to Pinpoint Test E
PCM P26D2:00 Engine Coolant Pump Control Module Over Temperature: No Sub Type Information GO to Pinpoint Test B
PCM P26D3:00 Engine Coolant Pump Supply Voltage Circuit: No Sub Type Information GO to Pinpoint Test E
PCM P2AFD:00 Engine Coolant Temperature Sensor 4 Circuit Range/Performance: No Sub Type Information GO to Pinpoint Test G
PCM P2AFE:00 Engine Coolant Temperature Sensor 4 Circuit Low: No Sub Type Information GO to Pinpoint Test G
PCM P2AFF:00 Engine Coolant Temperature Sensor 4 Circuit High: No Sub Type Information GO to Pinpoint Test G
PCM P2C22:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Position Sensor Circuit: No Sub Type Information GO to Pinpoint Test D
PCM P2C23:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Position Sensor Performance: No Sub Type Information GO to Pinpoint Test D
PCM U019F:00 Lost Communication With Engine Coolant Pump Control Module: No Sub Type Information GO to Pinpoint Test E

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Symptom Action

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Condition Actions
Loss of coolant   GO to Pinpoint Test A
The engine overheats.   GO to Pinpoint Test B
The engine does not reach normal operating temperature.   GO to Pinpoint Test C
The block heater does not operate correctly. (if equipped)
  • CHECK continuity in all 3 power cable circuits. If any circuit measures more than 5 ohms, INSTALL a new power cable.
  • CHECK the resistance of the block heater. If the resistance does not measure between 30 and 40 ohms, INSTALL a new block heater.
    REFER to: Block Heater (303-03C Engine Cooling, Removal and Installation).
The electric cooling fan is inoperative in one or more speeds or does not operate correctly.  
REFER to: Cooling Fan Control (303-03C Engine Cooling, Diagnosis and Testing).
The electric cooling fan stays on all the time.  
REFER to: Cooling Fan Control (303-03C Engine Cooling, Diagnosis and Testing).
Auxiliary coolant pump failure   GO to Pinpoint Test E

Pinpoint Tests


PINPOINT TEST A: LOSS OF COOLANT

Normal Operation and Fault Conditions

The engine cooling system is a closed system providing for coolant expansion and contraction as well as changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the cooling system.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P26CE:00 Engine Coolant Pump Overspeed/Air In System: No Sub Type Information Sets in the PCM when an engine overspeed the condition.

Possible Sources

  • Coolant hoses or tubes
  • Hose clamps
  • Thermostat O-ring seal or gasket
  • Coolant pump O-ring seal or gasket
  • Thermostat housing
  • Oil cooler (may leak internally or externally) (if equipped)
  • Transmission fluid warmer (may leak internally or externally)
  • Transmission fluid heater coolant control valve
  • Radiator
  • Pressure relief cap
  • Coolant pump leaking from weep hole
  • Cabin heater coolant pump (if equipped)
  • Heater core
  • Lower intake manifold
  • Engine gaskets (may leak internally or externally)
  • Degas bottle
  • Cylinder block core plugs
  • Cylinder head core plugs
  • Block heater (if equipped)

  WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.

A1 CARRY OUT INSPECTION AND VERIFICATION
  • Carry out Inspection and Verification.

Are any concerns present?
Yes REPAIR as needed.
No GO to A2

A2 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE ENGINE COOLING SYSTEM

NOTE: Allow the engine to cool before checking the engine coolant level.

  • Ignition OFF
  • Visually inspect the engine coolant level at the degas bottle and adjust as necessary. Pressure test the engine cooling system. Refer to Component Tests, Cooling System Pressure Test in this section.

Does the engine cooling system leak externally?
Yes REPAIR or INSTALL new components.
No GO to A3

A3 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK
  • Inspect the engine coolant in the degas bottle for signs of engine oil.

Is engine oil evident in the engine coolant?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to A4

A4 CHECK THE ENGINE OIL FOR COOLANT
  • Remove the oil level indicator from the engine.

Is coolant evident in the oil?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to A5

A5 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID
  • Check the engine coolant in the degas bottle for signs of transmission fluid.

Is transmission fluid evident in the engine coolant?
Yes INSTALL a new transmission fluid warmer.
REFER to: Transmission Fluid Cooler (307-02B Transmission Cooling - Automatic Transmission – HF45, Removal and Installation).
REPAIR the transmission as necessary. REFER to: DTC Chart and Pinpoint Tests - 1.5L EcoBoost (132kW/180PS) – I3 (Y1) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to A6

A6 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT
  • Remove the transmission oil leveling plug.
  • Check the transmission fluid for engine coolant.

Is engine coolant evident in the transmission fluid?
Yes INSTALL a new transmission fluid warmer.
REFER to: Transmission Fluid Cooler (307-02B Transmission Cooling - Automatic Transmission – HF45, Removal and Installation).
REPAIR the transmission as necessary. REFER to: DTC Chart and Pinpoint Tests - 1.5L EcoBoost (132kW/180PS) – I3 (Y1) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to A7

A7 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES

NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent.

  • Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases.

Are combustion gases present?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No Replace the coolant pump if P26CE code is present.
REFER to: Coolant Pump (303-03C Engine Cooling, Removal and Installation).

PINPOINT TEST B: THE ENGINE OVERHEATS

Normal Operation and Fault Conditions

The engine cooling system maintains the engine temperature during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P26D2:00 Engine Coolant Pump Control Module Over Temperature: No Sub Type Information Sets in the PCM when an engine overheat condition was sensed by the CHT sensor.
PCM P1299:00 Cylinder Head Overtemperature Protection Active: No Sub Type Information Sets in the PCM when an engine overheat condition was sensed by the CHT sensor.
PCM P0217:00 Engine Coolant Overtemperature Condition: No Sub Type Information Sets in the PCM when an engine overheat condition was sensed by the CHT sensor.

Possible Sources

  • Low coolant level
  • External engine coolant leak
  • Airlock in system
  • Pressure relief cap installation
  • Restricted airflow through A/C condenser/radiator
  • Internal engine coolant leak
  • Coolant condition/concentration
  • Non-OEM engine enhancement components
  • Electric cooling fan
  • CHT sensor
  • Radiator
  • Thermostat
  • Coolant pump
  • Coolant flow restriction
  • Active grill shutter assembly
B1 CARRY OUT INSPECTION AND VERIFICATION
  • Carry out the Inspection and Verification procedure in this section.

Are any concerns present?
Yes REPAIR as needed.
No GO to B2

B2 CHECK FOR PCM (POWERTRAIN CONTROL MODULE) DTCS
  • Ignition ON.
  • Using a scan tool, perform PCM self-test.

Is DTC P0217 and/or P1299 present?
Yes GO to B4
No Actual engine overheating has not been verified. CHECK the engine coolant temperature gauge operation.
REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
If any other PCM DTCs are retrieved,
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls, Diagnosis and Testing).

B3 CHECK FOR ACTIVE GRILL SHUTTER DTCS
  • Review the PCM DTCs.

Are any active grill shutter DTCs present?
Yes
REFER to: Active Grille Shutter (501-02 Front End Body Panels, Diagnosis and Testing).
No GO to B4

B4 CHECK FOR AN AIRFLOW OBSTRUCTION AND MISSING AIR DEFLECTORS

NOTE: Verify no vehicle front end damage is present.

  • Check the radiator or A/C condenser for an external obstruction such as leaves or cardboard and verify all air deflectors are present.

Is an airflow obstruction present or air deflectors missing?
Yes REPAIR as necessary.
No GO to B5

B5 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE COOLING SYSTEM
  • Ignition OFF.
  • Visually check the engine coolant level in the coolant expansion tank and adjust as necessary. Pressure test the cooling system.

Does the engine cooling system leak externally?
Yes REPAIR or INSTALL new components.
No GO to B6

B6 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK
  • Inspect the engine coolant in the coolant expansion tank for signs of engine oil.

Is engine oil evident in the coolant?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to B7

B7 CHECK THE ENGINE OIL FOR COOLANT
  • Remove the oil level indicator from the engine.

Is coolant evident in the oil?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to B8

B8 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID
  • Check the engine coolant in the degas bottle for signs of transmission fluid.

Is transmission fluid evident in the engine coolant?
Yes INSTALL a new transmission fluid cooler.
REFER to: Transmission Fluid Cooler (307-02B Transmission Cooling - Automatic Transmission – HF45, Removal and Installation).
REPAIR the transmission as necessary.REFER to: DTC Chart and Pinpoint Tests - 1.5L EcoBoost (132kW/180PS) – I3 (Y1) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to B9

B9 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT
  • Remove the transmission oil leveling plug.
  • Check the transmission fluid for engine coolant.

Is engine coolant evident in the transmission fluid?
Yes INSTALL a new transmission fluid cooler.
REFER to: Transmission Fluid Cooler (307-02B Transmission Cooling - Automatic Transmission – HF45, Removal and Installation).
REPAIR the transmission as necessary.REFER to: DTC Chart and Pinpoint Tests - 1.5L EcoBoost (132kW/180PS) – I3 (Y1) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to B10

B10 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES

NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent.

  • Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases.

Are combustion gases present?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to B11

B11 CHECK COOLANT CONDITION
  • Check the coolant for dirt, rust or contamination and check the coolant concentration.

Is the coolant condition OK?
Yes GO to B12
No FLUSH the engine cooling system.
REFER to: Engine Cooling System Flushing (303-03C Engine Cooling, General Procedures).

B12 CHECK THE ELECTRIC COOLING FAN OPERATION
  • Start the engine.
  • Place the climate control function selector in the MAX A/C position and the blower motor switch in the HI position.

Did the electric cooling fan operate?
Yes GO to B13
No DIAGNOSE the electric cooling fan operation.
REFER to: Cooling Fan Control (303-03C Engine Cooling, Diagnosis and Testing).

B13 CHECK THE COOLANT PUMP OPERATION
  • Start the engine.
  • Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT position. Feel the heater outlet hose.

Is the heater outlet hose hot?
Yes GO to B14
No INSTALL a new coolant pump.
REFER to: Coolant Pump (303-03C Engine Cooling, Removal and Installation).

B14 CHECK THE THERMOSTAT OPERATION

NOTE: This cooling system uses a cold side thermostat. The coolant in the radiator must reach full operating temperature for the thermostat to remain in an open state.

  • Start the engine.
  • Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT position. Feel the lower radiator hose.

Is the lower radiator hose hot?
Yes CHECK the temperature gauge operation.
REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
No GO to B15

B15 VISUALLY INSPECT THE THERMOSTAT
  • Carry out the Thermostat Visual Inspection in the Component Tests portion of this section.

Is the thermostat damaged?
Yes INSTALL a new thermostat.
REFER to: Thermostat Housing (303-03C Engine Cooling, Removal and Installation).
No INSTALL a new thermostat.
REFER to: Thermostat Housing (303-03C Engine Cooling, Removal and Installation).
If the engine still overheats, INSTALL a new radiator.REFER to: Radiator (303-03C Engine Cooling, Removal and Installation).

PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

Normal Operation and Fault Conditions

The engine cooling system maintains engine temperature during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant is sent from the coolant pump through the engine block and cylinder head. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit in order to transfer engine generated heat to the outside air.

Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant flow through some coolant circuits (radiator, heater core) is more than expected given the conditions. Heat is not allowed to build in the engine because a heat exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition, perceived concerns that the engine does not reach normal operating temperature can be related to a low coolant level or trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P0125:00 Insufficient Coolant Temp For Closed Loop Fuel Control: No Sub Type Information Sets in the PCM when the CHT sensor has not achieved the required temperature level to enter closed loop operating conditions within a specified amount of time after starting the engine.
PCM P0128:00 Coolant Thermostat (Coolant Temp Below Thermostat Regulating Temperature): No Sub Type Information Sets in the PCM when the thermostat monitor has not achieved the required engine operating temperature within a specified amount of time after starting the engine.

Possible Sources

  • Low coolant level
  • Thermostat
  • Temperature gauge
  • CHT

  WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.

C1 CARRY OUT INSPECTION AND VERIFICATION
  • Carry out the Inspection and Verification procedure in this section.

Were any concerns found?
Yes REPAIR as needed.
No GO to C2

C2 CHECK FOR DTC P0125 OR P0128
  • Using a scan tool, perform the PCM self-test.

Is DTC P0125 or P0128 present?
Yes If P2C22, P2C23, P237C, P237D, P237E or P237F are also present, GO to Pinpoint Test D GO to C3
No The cooling system is operational. If an inoperative temperature gauge is suspected, CHECK the temperature gauge operation.
REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
If an inoperative climate control system is suspected, CHECK the climate control system operation. REFER to: Climate Control System - Vehicles With: Dual Automatic Temperature Control (DATC)/Electronic Automatic Temperature Control (EATC) (412-00 Climate Control System - General Information, Diagnosis and Testing).
If any other Diagnostic Trouble Codes (DTCs) are retrieved, REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls, Diagnosis and Testing).

C3 CHECK THE COOLANT LEVEL

NOTE: Allow the engine to cool before checking the coolant expansion tank.

  • Visually check the engine coolant level in the coolant expansion tank

Is the engine coolant level within specification?
Yes INSTALL a new thermostat.
REFER to: Thermostat Housing (303-03C Engine Cooling, Removal and Installation).
CLEAR Diagnostic Trouble Codes (DTCs). If the DTC returns check for correct CHT sensor operation.
No GO to Pinpoint Test A

PINPOINT TEST D: EXHAUST HEAT EXCHANGER EXHAUST BYPASS VALVE

Refer to Wiring Diagrams Cell 23 for schematic and connector information.

Normal Operation and Fault Conditions

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P237F:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Performance: No Sub Type Information This DTC sets when the PCM senses a valid position but has not changed since start up.
PCM P2C22:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Position Sensor Circuit: No Sub Type Information This DTC sets when the PCM senses a valid position but has not changed since start up.
PCM P237C:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Circuit/Open: No Sub Type Information This DTC sets when the PCM senses an open circuit to the exhaust heat exchanger exhaust bypass valve.
PCM P237D:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Circuit Low: No Sub Type Information This DTC sets when the PCM senses low voltage on the exhaust heat exchanger exhaust bypass valve.
PCM P237E:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Control Circuit High: No Sub Type Information This DTC sets when the PCM senses high voltage on the exhaust heat exchanger exhaust bypass valve.
PCM P2C23:00 Exhaust Heat Exchanger Exhaust Bypass Valve 'A' Position Sensor Performance: No Sub Type Information This DTC sets when the PCM senses a mismatch in the commanded and received heat exchanger valve position and the coolant temperature difference between inlet and outlet is within range.

Possible Sources

  • Wiring, terminals or connectors
  • BJB Fuse 8 (15A).
  • PCM
  • Frozen valve / Broken linkages
  • Valve alignment
  • Faulty position sensor
  • Clogged heat exchanger
  • Hoses
  • Coolant leaks
D1 RETRIEVE AND RECORD ALL DTCS
  • Start the vehicle and allow engine to reach normal operating temperatures. Using the diagnostic scan tool, retrieve all DTCs.

Was DTC P237C, P237D, P237E, P237F, P2C22 or P2C23 set?
Yes GO to D2
No GO to D4

D2 CHECK THE EXHAUST HEAT EXCHANGER PID

  • Access the  PCM  and monitor the  EHE_EBVA_POS_ST  PID

  • Record the fault status codes.

Is fault status code 3 or 160 hZ present?
Yes SWITCH the ignition to the OFF position. GO to D3
No GO to D4

D3 CHECK THE EXHAUST HEAT EXCHANGER FOR DAMAGE
  • Visually inspect the exhaust heat exchanger for damage or signs of failure.
  • Residual condensation from normal operation can freeze the exhaust heat exchanger valve restricting its movement. Using the Hybrid Engine Running Diagnostic Mode, run the engine to operating temperature to melt any residual ice build-up in the exhaust heat exchanger.

  • Access the  PCM  and monitor the  EHE_EBVA_POS_ST  PID

  • Using the diagnostic scan tool, retrieve all DTCs.
  • Record the fault status codes.

Was DTC P237C, P237D, P237E, P237F, P2C22 or P2C23 set and is fault status code 3 or 160 hZ present?
Yes INSTALL a new muffler inlet pipe.
REFER to: Muffler and Tailpipe - Full Hybrid Electric Vehicle (FHEV) (309-00C Exhaust System, Removal and Installation).
No CLEAR Diagnostic Trouble Codes (DTCs). GO to D4

D4 CHECK THE EXHAUST HEAT EXCHANGER EXHAUST BYPASS VALVE CIRCUITS FOR A SHORT TO VOLTAGE
  • Disconnect BJB Fuse 8 (15A).
  • Disconnect PCM C1381B .
  • Disconnect Exhaust heat exchanger exhaust bypass valve C3236 .
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3236-2   Ground
      C3236-3   Ground
      C3236-4   Ground

Is there any voltage present?
Yes REPAIR the circuit.
No GO to D5

D5 CHECK THE EXHAUST HEAT EXCHANGER EXHAUST BYPASS VALVE CIRCUITS FOR A SHORT TO GROUND
  • Ignition OFF.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3236-2   Ground
      C3236-3   Ground

Are the resistances greater than 10,000 ohms?
Yes GO to D6
No REPAIR the circuit.

D6 CHECK THE EXHAUST HEAT EXCHANGER EXHAUST BYPASS VALVE CIRCUITS FOR AN OPEN
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3236-1   Ground

    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3236-3 BJB fuse 8 (15A) cavity, component side

    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3236-2   C1381B-63
      C3236-4   C1381B-8

Are the resistances less than 3 ohms?
Yes GO to D7
No REPAIR the circuit.

D7 CHECK THE EXHAUST HEAT EXCHANGER EXHAUST BYPASS VALVE CIRCUITS FOR A SHORT TOGETHER
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3236-1   C3236-2
      C3236-1   C3236-3
      C3236-1   C3236-4
      C3236-2   C3236-3
      C3236-2   C3236-4
      C3236-3   C3236-4

Are the resistances greater than 10,000 ohms?
Yes GO to D8
No REPAIR the circuit.

D8 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Ignition OFF.
  • Disconnect and inspect all PCM connectors.
  • Repair:
    • corrosion (replace connector or terminals – clean module pins)
    • damaged or bent pins – replace terminals/pins
    • pushed-out pins – replace pins as necessary
  • Reconnect all PCM connectors. Make sure they seat and latch correctly.
  • Operate the system and verify the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable service articles: TSB , GSB , SSM or FSA . If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern,
   VIN required to access Guided Routine (PCM) If the condition is still present, INSTALL a new muffler inlet pipe.
REFER to: Muffler and Tailpipe - Full Hybrid Electric Vehicle (FHEV) (309-00C Exhaust System, Removal and Installation).
No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

PINPOINT TEST E: THE ELECTRIC COOLANT PUMP IS INOPERATIVE OR DOES NOT OPERATE CORRECTLY

Refer to Wiring Diagrams Cell 33 for schematic and connector information.

Normal Operation and Fault Conditions

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P26CB:00 Engine Coolant Pump Performance/Stuck Off: No Sub Type Information This DTC sets when the PCM senses a valid position but has not changed since start up.
PCM U019F:00 Lost Communication With Engine Coolant Pump Control Module: No Sub Type Information When the PCM does not receive communication from the engine coolant pump control module for a predetermined amount of time, the PCM sets this DTC .
PCM P26D3:00 Engine Coolant Pump Supply Voltage Circuit: No Sub Type Information The engine coolant pump control module does not communicate the power and ground circuit status to the PCM . If either of these lines is faulted, the coolant pump will not run and there will be no LIN communication between the engine coolant pump control module and the PCM . The PCM first check for a fault on the LIN . The PCM sets this DTC when the LIN is faulted and the ECT increases more than 10°C (18°F).
PCM P26D1:00 Engine Coolant Pump Control Module System Voltage High: No Sub Type Information The engine coolant pump control module communicates the control module voltage to the PCM via the LIN . The PCM sets this DTC when the voltage is greater than PCM battery voltage plus 4 volts for a predetermined amount of time.
PCM P26D0:00 Engine Coolant Pump Control Module System Voltage Low: No Sub Type Information The engine coolant pump control module communicates the control module voltage to the PCM via the LIN . The PCM sets this DTC when the voltage is less than PCM battery voltage minus 4 volts for a predetermined amount of time.
PCM P26CA:00 Engine Coolant Pump Control Circuit/Open: No Sub Type Information When the electric coolant pump module senses no power in the control circuit, it sends a message to the PCM via the LIN . The PCM sets this DTC when the fault is communicated for a predetermined amount of time.

Possible Sources

  • Wiring, terminals or connectors
  • BJB Fuse 123 (50A).
  • BJB Fuse 8 (15A).
  • PCM
  • Electric coolant pump
E1 CHECK THE ELECTRIC COOLANT PUMP ELECTRICAL CONNECTOR, FUSES, AND CHASSIS GROUND
  • DISCONNECT and INSPECT the electric coolant pump C1052 for corrosion or water intrusion if no concerns are present CONNECT the electric coolant pump C1052 and VERIFY it is fully seated.
  • CONNECT the electric coolant pump C1052. VERIFY the electric coolant pump C1052 is fully seated.
  • VERIFY BJB fuse 123 (50A) is OK. If the fuse is OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.
  • VERIFY BJB fuse 8 (15A) is OK. If the fuse is OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the possible causes of the circuit short.
  • INSPECT G115 for being clean and tight.

Were any concerns present?
Yes Address the concern. Using a scan tool, clear the PCM Diagnostic Trouble Codes (DTCs) and repeat the self test. If Diagnostic Trouble Codes (DTCs) are not present the concern is repaired. If Diagnostic Trouble Codes (DTCs) are present, GO to E3
No Using a scan tool, clear the PCM Diagnostic Trouble Codes (DTCs) and perform the PCM self-test. If no Diagnostic Trouble Codes (DTCs) are present, GO to E2

E2 PERFORM A WIGGLE TEST WHILE USING THE ACTIVE COMMAND FUNCTION ON THE SCAN TOOL
  • Ignition ON.
  • Using a diagnostic scan tool, view PCM PIDs.
  • NOTE: The COOLPUMP_CMD# PID may not be available on some vehicles. If the PID is not available continue to pinpoint test step E3. Using the output state control command COOLPMP_CMD# ON.
  • Listen for the electric coolant pump while performing a wiggle test on the wiring harness.
  • Using the output state control command COOLPMP_CMD# OFF.
  • Listen for the electric coolant pump while performing a wiggle test on the wiring harness.

Did the electric coolant pump remain ON and remain OFF when using output state control?
Yes Using a scan tool, perform PCM self-test. If Diagnostic Trouble Codes (DTCs) repeat the concern may be caused by connections. Address the root cause of any connector, pin, or wiring issues.
No GO to E3

E3 RECORD THE PCM (POWERTRAIN CONTROL MODULE) DIAGNOSTIC TROUBLE CODES (DTCS)
  • Using a scan tool, record the PCM Diagnostic Trouble Codes (DTCs).

Are Diagnostic Trouble Codes (DTCs) P26CA, P26D0, P26D1, P26D3, P26CB and/or U019F present?
Yes For Diagnostic Trouble Codes (DTCs) P26CA, P26D0, P26D1, P26D3 or P26CB with or without U019F present, GO to E4 For DTC P26CA without other Diagnostic Trouble Codes (DTCs) present, GO to E6 For DTC U019F without other Diagnostic Trouble Codes (DTCs) present, GO to E7 For all other PCM Diagnostic Trouble Codes (DTCs) on vehicles,
REFER to: Electronic Engine Controls (303-14C Electronic Engine Controls, Diagnosis and Testing).
No The system is operating correctly at this time. The concern may have been caused by connections. Address the root cause of any connector or pin issues.

E4 CHECK THE ELECTRIC COOLANT PUMP SUPPLY CIRCUIT VOLTAGE
  • Disconnect: Electric Coolant Pump C1052.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-2   Ground

Is the voltage greater than 11 volts?
Yes GO to E5
No VERIFY high current battery junction box fuse 123 (50A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the cause of the short circuit.

E5 CHECK THE ELECTRIC COOLANT PUMP GROUND CIRCUIT FOR AN OPEN
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-1   Ground

Is the resistance less than 3 ohms?
Yes GO to E6
No REPAIR the circuit.

E6 CHECK THE ELECTRIC COOLANT PUMP CONTROL CIRCUIT VOLTAGE
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-3   Ground

Is the voltage greater than 11 volts?
Yes INSTALL a new electric coolant pump.
REFER to: Coolant Pump (303-03C Engine Cooling, Removal and Installation).
CLEAR the Diagnostic Trouble Codes (DTCs). If DTC P26CA is still present, GO to E12
No VERIFY BJB fuse 8 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams manual to identify the cause of the short circuit.

E7 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR AN OPEN
  • Ignition OFF.
  • Disconnect: Electric Coolant Pump C1052.
  • Disconnect: PCM C1381B.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-4   C1381B-74

Is the resistance less than 3 ohms?
Yes GO to E8
No REPAIR the circuit.

E8 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) FOR A SHORT TO VOLTAGE
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-4   Ground

Is any voltage present?
Yes GO to E9
No GO to E10

E9 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) FOR A SHORT TO VOLTAGE WITH THE ACTIVE GRILLE SHUTTER ACTUATOR DISCONNECTED
  • Ignition OFF.
  • Disconnect: Active Grille Shutter Actuator C1651.
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-4   Ground

Is any voltage present?
Yes REPAIR the circuit.
No INSTALL a new active grille shutter.
REFER to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation).

E10 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND
  • Ignition OFF.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-4   Ground

Is the resistance greater than 10,000 ohms?
Yes INSTALL a new electric coolant pump.
REFER to: Coolant Pump (303-03C Engine Cooling, Removal and Installation).
CLEAR the Diagnostic Trouble Codes (DTCs). If DTC U019F is still present, GO to E12.
No GO to E11

E11 CHECK THE LIN (LOCAL INTERCONNECT NETWORK) CIRCUIT FOR A SHORT TO GROUND WITH THE ACTIVE GRILLE SHUTTER ACTUATOR DISCONNECTED
  • Disconnect: Active Grille Shutter Actuator C1651.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C1052-4   Ground

Is the resistance greater than 10,000 ohms?
Yes INSTALL a new active grille shutter.
REFER to: Active Grille Shutter (501-02 Front End Body Panels, Removal and Installation).
No REPAIR the circuit.

E12 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Ignition OFF.
  • Disconnect and inspect PCM C1381B.
  • Repair:
    • corrosion (install new connector or terminals – clean module pins)
    • damaged or bent pins – install new terminals/pins
    • pushed-out pins – install new pins as necessary
  • Reconnect the PCM connector. Make sure it seats and latches correctly.
  • Operate the system and determine if the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable TSBs. If a TSB exists for this concern, discontinue this test and follow TSB instructions. If no TSBs address this concern,
   VIN required to access Guided Routine (PCM) .
No The system is operating correctly at this time. The concern may have been caused by module connections. Address the root cause of any connector or pin issues.

PINPOINT TEST F: ENGINE COOLANT TEMPERATURE SENSOR 3

Refer to Wiring Diagrams Cell 23 for schematic and connector information.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P01E5:00 Engine Coolant Temperature Sensor 3 Circuit Low: No Sub Type Information This DTC sets when the PCM senses low voltage on the ECT sensor 3 circuit, indicating a short to ground.
PCM P01E4:00 Engine Coolant Temperature Sensor 3 Circuit Range/Performance: No Sub Type Information This DTC sets when the PCM senses voltage out of range on the ECT sensor 3 circuit.
PCM P01E6:00 Engine Coolant Temperature Sensor 3 Circuit High: No Sub Type Information This DTC sets when the PCM senses high voltage on the ECT sensor 3 circuit, indicating a short to voltage.

Possible Sources

  • Wiring, terminals or connectors
  • ECT sensor 3
  • PCM

  WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

NOTE: Before performing this pinpoint test, ensure the high voltage battery is at least 50 % charged. For charging information, refer to section 414-03.

F1 CHECK THE COOLANT HOSE ROUTING

NOTE: Routing of the coolant hoses is critical to proper engine cooling system operation.

  • Ignition OFF.
  • Check the cabin coolant heater system hose routing. Pay close attention to the diverter valve hose routing and the top and bottom ports of the bulkhead. View the system diagrams, Refer to the appropriate Description and Operation procedure in Group 303-03.

Are the coolant hoses routed correctly?
Yes CLEAR all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules. TEST system for normal operation. If the concern is still present, GO to F2
No CORRECT the coolant hose routing. Refer to the appropriate Description and Operation procedure in Group 303-03.

F2 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3 CIRCUITS FOR A SHORT TO VOLTAGE
  • Ignition OFF.
  • Disconnect PCM C1381B .
  • Disconnect ECT Sensor 3 C3235 .
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3235-1   Ground

Is there any voltage present?
Yes REPAIR the circuit in question.
No GO to F3

F3 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3 CIRCUITS FOR A SHORT TO GROUND
  • Ignition OFF.
  • Disconnect joint connector C126 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3235-1   Ground
      C3235-2   Ground

Are the resistances greater than 10,000 ohms?
Yes GO to F4
No REPAIR the circuit in question.

F4 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3 CIRCUITS FOR AN OPEN
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3235-1   C126-7
      C3235-2   C126-8
      C126-7   C1381B-45

Are the resistances less than 3 ohms?
Yes GO to F5
No REPAIR the circuit in question.

F5 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3 CIRCUITS FOR A SHORT TOGETHER
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3235-1   C3235-2

Is the resistance greater than 10,000 ohms?
Yes GO to F6
No REPAIR the circuits.

F6 CHECK THE RESISTANCE OF THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 3
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
    ECT Sensor 3 Connector Pin 1, Component Side ECT Sensor 3 Connector Pin 2, Component Side

Is the resistance between 0.527-1108 KOhms and does the resistance increase and decrease inversely proportional to engine coolant temperature?
Yes GO to F7
No Install a new ECT sensor 3.
REFER to: Engine Coolant Temperature (ECT) Sensor (303-14C Electronic Engine Controls, Removal and Installation).

F7 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Ignition OFF.
  • Disconnect and inspect the PCM connectors.
  • Repair:
    • corrosion (replace connector or terminals – clean module pins)
    • damaged or bent pins – replace terminals/pins
    • pushed-out pins – replace pins as necessary
  • Reconnect the PCM connectors. Make sure they seat and latch correctly.
  • Operate the system and verify the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable service articles: TSB , GSB , SSM or FSA . If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern,
   VIN required to access Guided Routine (PCM)
No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.

PINPOINT TEST G: ENGINE COOLANT TEMPERATURE SENSOR 4

Refer to Wiring Diagrams Cell 23 for schematic and connector information.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P2AFF:00 Engine Coolant Temperature Sensor 4 Circuit High: No Sub Type Information This DTC sets when the PCM senses high voltage on the ECT sensor 4 circuit, indicating a short to voltage.
PCM P2AFD:00 Engine Coolant Temperature Sensor 4 Circuit Range/Performance: No Sub Type Information This DTC sets when the PCM senses voltage out of range on the ECT sensor 4 circuit.
PCM P2AFE:00 Engine Coolant Temperature Sensor 4 Circuit Low: No Sub Type Information This DTC sets when the PCM senses low voltage on the ECT sensor 4 circuit, indicating a short to ground.

Possible Sources

  • Wiring, terminals or connectors
  • ECT sensor 4
  • PCM

  WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.

NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector.

NOTE: Before performing this pinpoint test, ensure the high voltage battery is at least 50 % charged. For charging information, refer to section 414-03.

G1 CHECK THE COOLANT HOSE ROUTING

NOTE: Routing of the coolant hoses is critical to proper engine cooling system operation.

  • Ignition OFF.
  • Check the cabin coolant heater system hose routing. Pay close attention to the diverter valve hose routing and the top and bottom ports of the bulkhead. View the system diagrams, Refer to the appropriate Description and Operation procedure in Group 303-03.

Are the coolant hoses routed correctly?
Yes CLEAR all Continuous Memory Diagnostic Trouble Codes (CMDTCs) from all modules. TEST system for normal operation. If the concern is still present, GO to G2
No CORRECT the coolant hose routing. Refer to the appropriate Description and Operation procedure in Group 303-03.

G2 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4 CIRCUITS FOR A SHORT TO VOLTAGE
  • Ignition OFF.
  • Disconnect PCM C1381B .
  • Disconnect ECT Sensor 4 C3233 .
  • Ignition ON.
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3233-1   Ground

Is there any voltage present?
Yes REPAIR the circuit in question.
No GO to G3

G3 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4 CIRCUITS FOR A SHORT TO GROUND
  • Ignition OFF.
  • Disconnect joint connector C126 .
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3233-1   Ground
      C3233-2   Ground

Are the resistances greater than 10,000 ohms?
Yes GO to G4
No REPAIR the circuit in question.

G4 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4 CIRCUITS FOR AN OPEN
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3233-1   C126-9
      C3233-2   C126-31
      C126-9   C1381B-17

Are the resistances less than 3 ohms?
Yes GO to G5
No REPAIR the circuit in question.

G5 CHECK THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4 CIRCUITS FOR A SHORT TOGETHER
  • Measure:
    Click to display connectors
    Positive Lead Measurement / Action Negative Lead
      C3233-1   C3233-2

Is the resistance greater than 10,000 ohms?
Yes GO to G6
No REPAIR the circuits.

G6 CHECK THE RESISTANCE OF THE ECT (ENGINE COOLANT TEMPERATURE) SENSOR 4
  • Measure:
    Positive Lead Measurement / Action Negative Lead
    ECT Sensor 4 Connector Pin 1, Component Side ECT Sensor 4 Connector Pin 2, Component Side

Is the resistance between 0.527-1108 KOhms and does the resistance increase and decrease inversely proportional to engine coolant temperature?
Yes GO to G7
No Install a new ECT sensor 4.
REFER to: Engine Coolant Temperature (ECT) Sensor (303-14C Electronic Engine Controls, Removal and Installation).

G7 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Ignition OFF.
  • Disconnect and inspect the PCM connectors.
  • Repair:
    • corrosion (replace connector or terminals – clean module pins)
    • damaged or bent pins – replace terminals/pins
    • pushed-out pins – replace pins as necessary
  • Reconnect the PCM connectors. Make sure they seat and latch correctly.
  • Operate the system and verify the concern is still present.

Is the concern still present?
Yes CHECK OASIS for any applicable service articles: TSB , GSB , SSM or FSA . If a service article exists for this concern, DISCONTINUE this test and FOLLOW the service article instructions. If no service articles address this concern,
   VIN required to access Guided Routine (PCM)
No The system is operating correctly at this time. The concern may have been caused by module connections. ADDRESS the root cause of any connector or pin issues.


Component Tests

Cooling System Pressure Test

  WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.

NOTE: Vehicles have a pressure relief cap on the degas bottle and no radiator cap.

  1. Turn the engine OFF.
  1. Check the engine coolant level and adjust as necessary.
  1. Remove the degas bottle cap. Inspect the degas bottle cap and degas bottle for any issues that would cause improper sealing, such as for cross-threading, burrs, damaged o-ring, etc. If any issues are found, or if coolant was expelled through the cap potentially leaving contamination in the gasket, INSTALL a new cap and/or degas bottle.
  1. Attach the Pressure Tester and adaptor (Snap-On TA53 or equivalent), to the degas bottle cap. The cap must hold pressure of 145 kPa +/- 21 kPa (21 PSI +/- 3 PSI). If any issues are found, INSTALL a new cap.
  1. Attach the Pressure Tester and adaptor (Snap-On TA52, AST ASSFZ-47, Redline RDL95-0750 or equivalent) to the degas bottle.

  1. NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the Specifications table in this section or cooling system components may be damaged.

    NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading results.

    To pressurize the engine cooling system, slowly press the plunger of the pressure test pump and increase the pressure to between 124 - 138 kPa (18 - 20 PSI). Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.
  1. If no leaks are found and the pressure drops, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant.
    REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
  1. If the pressure does not drop remove the cooling system Pressure Tester and adaptor from degas bottle.
  1. Install the degas bottle cap until it contacts the hard stop.

Thermostat

Install a new thermostat only after at least one of the following tests and checks have been carried out:

  • Pinpoint Test B or C
  • Thermostat Visual Inspection

Thermostat Visual Inspection

  1. Remove the thermostat.
  1. Examine the thermostat for signs of damage including:
  • Valve not fully seated (light visible through the valve)
  • Foreign material lodged in the main valve
  • Bent or broken frame or flange
  • Bent or broken spring
  • Wax leaking from wax reservoir or a bulge in the reservoir
  • Any other damage or distortion

  1. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot water or other heat sources. This method is not an accurate means to test the function of the thermostat and may damage the thermostat.

    If damage is found during the inspection, remove any foreign material or broken pieces and install a new thermostat.

Radiator Leak Test, Removed From Vehicle

NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators.

NOTE: Clean the radiator before leak testing to avoid contamination of tank.

  1. Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the Specifications table.

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