Engine - Unexplained Low Engine Coolant Level
LTB00502NAS212 FEB 2013
SECTION: 303-01A/B
Continual Unexplained Low Coolant Issues
AFFECTED VEHICLE RANGE:
MARKETS:
NAS
CONDITION SUMMARY:
Situation: A continual unexplained low engine coolant level may be evident, with no leak evident from the engine coolant system.
NOTE:
Any faults found other than a leaking cylinder head core plug(s) must be carried out as a separate claim.
Cause: This may be caused by coolant loss through the threaded core plugs in the engine cylinder head.
Action: In the event of a customer concern of the above, refer to the Repair Procedure outlined below.
PARTS:
WARRANTY:
SERVICE INSTRUCTION:
NOTE:
This procedure should only be carried Out after a thorough inspection has shown no other causes of coolant loss For further information refer to TOPIx Workshop Manual, section 303-03A/B:
Engine Cooling GTDi 2.0L Petrol Engine Cooling Diagnosis and Testing.
1. Remove the valve cover (TOPIx Workshop Manual section 303-01A/B: Valve Cover).
2. Using a suitable coolant system pressure tester, pressurize the coolant system.
3. NOTE:
Do not remove the core plug(s) at this stage Inspect both core plugs for signs of coolant leakage and/or congealed oil.
4. Inspect the core plugs for signs of coolant leakage.
^ If signs of coolant leakage are evident, carry on to step 6.
^ If signs of congealed oil and coolant leakage are evident, carry on to step 6.
5. NOTE:
Fresh engine oil may be evident due to spillage when the valve cover is removed.
Inspect the core plugs for signs of coolant leakage.
^ If signs of congealed oil are evident, carry on to step 6.
^ If no signs of congealed oil or coolant leakage are evident, carry on to step 13.
6. De-pressurize the coolant system.
7. Carry out a coolant system partial drain (TOPIx Workshop Manual section 303-03A/B: Cooling System Partial Draining, Filling and Bleeding).
8. Using a suitable cleaning fluid and cloth, clean any excess oil and/or coolant from around the core plugs and the spark plugs.
9. NOTE:
The core plug can be re-used if no signs of damage are evident.
Reseal the leaking core plug.
^ Remove the core plug.
^ Clean and dry both threads.
^ Inspect the threads for signs of damage.
^ Apply a continuous bead of Loctite(R) 243 to the core plug thread.
^ Install the core plug and tighten to 75 Nm.
^ If required, repeat the above steps to the other core plug.
10. WARNING:
Do not start the engine.
Fill the engine with coolant (TOPIx Workshop Manual section 303-03A/B: Cooling System Partial Draining, Filling and Bleeding).
^ Carry out steps 2-4 of the coolant filling procedure.
11. CAUTION:
Allow the Loctite(R) 243 to cure for at least one (1) hour before pressurizing the coolant system.
Using a suitable coolant system pressure tester, pressurize the coolant system.
12. Inspect both core plugs for signs of coolant leakage.
^ If there are signs of coolant leakage from the core plug(s), carry out the necessary rectification procedure.
^ If there are no signs of coolant leakage from the core plug(s), carry on to step 13.
13. De-pressurize the coolant system and remove the coolant system pressure tester.
14. NOTE:
Make sure that the area around the core plugs and spark plugs is clean and free from coolant, oil, and debris.
Install the valve cover (see TOPIx Workshop Manual, section 303-01A/B).
15. NOTE:
Only carry Out this step if the coolant has been drained previously.
NOTE:
Do not install the engine undershield until after the engine oil and filter has been renewed.
Fill the engine with coolant (TOPIx Workshop Manual, section 303-03A/B: Cooling System Partial Draining, Filling and Bleeding).
^ Carry out only steps 5-13 of the coolant filling procedure.
16. NOTE:
Only carry Out this step if the core plug(s) required re-sealing.
Renew the engine oil and filter (see TOPIx Workshop Manual, section 303-01A/B: Valve Cover).
Disclaimer