For 1990-2009 cars

Step | Action | Value | Yes | No
--- | --- | --- | --- | ---
1 |

1. Check for a wrong or defective radiator fill cap.
2. Do a cap pressure test. Refer to Thermostat Diagnosis . If necessary, replace the filler cap.

Is there still a coolant loss?

124 kPa (18 psi)

Go to Step 2

System OK

2 |

1. Check for a distorted radiator fill neck.
2. If the upper sealing area of the fill neck is distorted, use a wood block and a mallet to reshape the neck in order to fit the cap.

Is there still a coolant loss?

--

Go to Step 3

System OK

3 |

1. Check for a leaking coolant recovery reservoir.
2. Check for a loose or damaged reservoir hose.
3. If the reservoir or hose is damaged, replace the reservoir or the hose. Refer to Coolant Recovery Reservoir Replacement .

Is there still a coolant loss?

--

Go to Step 4

System OK

4 |

1. Check for any loose or damaged radiator hoses or heater hoses and connections.
2. Re-seat the hoses and clamps. If necessary, replace the hoses and the clamps. Refer to Radiator Hose Replacement .

Is there still a coolant loss?

--

Go to Step 5

System OK

5 |

1. Check for a water pump gasket leak.
2. If necessary, replace the water pump gasket. Refer to Water Pump Replacement .

Is there still a coolant loss?

--

Go to Step 6

System OK

6 |

1. Check for a seal leak at the water pump.
2. If the seal is leaking, replace the water pump. Refer to Water Pump Replacement .

Is there still a coolant loss?

--

Go to Step 7

System OK

7 |

1. Check if the cylinder head bolts are tightened to specification. Refer to Section 6A.
2. Tighten the cylinder head bolts to the specification. If necessary, replace the cylinder head gasket. Refer to Section 6A.

Is there still a coolant loss?

--

Go to Step 8

System OK

8 |

1. Check for any coolant leaks at the radiator.
2. Inspect the radiator.
3. If necessary, replace the radiator. Refer to Radiator Replacement .

Is there still a loss of coolant?

--

Go to Step 9

System OK

9 |

1. Check the following for leaks:

• | The intake manifold 3800 (VIN K)

• | The cylinder head gasket

• | The engine block coolant drain hole plug or the knock sensor

• | The heater core

2. Make the necessary repairs or replace the components as necessary in order to repair the leak.

Is the repair complete?

--

System OK

--