For 1990-2009 cars

# EI06042 - 2.2L L61 Coolant Loss, Leak, No OVerheat Condition (Engineering Information)

Subject: | EI06042 - 2.2L L61 Coolant Loss, Leak, No Overheat Condition (Engineering Information)

Models: | 2007-2008 Chevrolet Cobalt, HHR, Malibu

| 2007-2008 Pontiac G5

| 2007 Saturn ION

| with 2.2L Engine (VINs D, F -- RPO L61)

Attention: | Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition or the EI does not show in GMVIS, disregard the bulletin and proceed with diagnostics found in published Service Information. THIS IS NOT A RECALL - refer to Service Bulletin 04-00-89-053A for more details on the use of Engineering Information bulletins.

This bulletin is being updated to add the heater core and drain tube to the list of components to inspect (Step 13). Please discard Corporate Bulletin Number 06-06-02-013C (Section 06 - Engine).

### Condition

Important: If the customer did not bring their vehicle in for this condition, do not proceed with this bulletin.

Some customers may comment on any of the following conditions:

• | Loss of coolant

• | Insufficient heat to the passenger compartment

• | MIL on/coolant (temperature) light illuminated

### Cause

GM Engineering is attempting to determine the root cause of coolant loss. General Motors has a need to obtain technical information first hand from the dealer technician DURING diagnosis and BEFORE repair. As a result, this information will be used by Engineering to help "root cause" the customer's concern and develop/validate a field fix.

### Correction

Important: The information from the following steps MUST be documented on, or attached to, the repair order.

During the diagnosis of the customer's concern, observe and document the following information on the repair order:

1. What was the customer's concern? Be specific.
2. Check for and list any DTCs that are set or stored in history.
3. Document the percentage of oil life remaining and/or miles (kilometers) since the last oil change.
4. Are any aftermarket devices installed that could affect the operation of the cooling system? If so, describe.

Caution: Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders, and the person removing the cap. Serious bodily injury may result.

5. What is the coolant level in the radiator surge tank?
6. Is the coolant at the proper level?

Important: It is important to use ONLY the J 46366 DEX-COOL® Leak Detection Dye. Other dyes may cause DEX-COOL® to appear green on a black background or coolant jar, causing a technician to add conventional coolant to a low system, which will contaminate the system. J 46366 dye fluoresces orange in color and causes little change in overall DEX-COOL® color appearance.

7. Apply J 46366 DEX-COOL® Leak Detection Dye to the coolant.
8. Does the engine crankshaft rotate?
9. Is the engine knocking?
10. Idle the engine at normal operating temperature. Is heavy, white smoke coming from the exhaust pipe?
11. Does the coolant recovery system discharge coolant while the engine is idling?
12. Inspect for kinked or pinched surge tank hoses, and/or leaks from hoses, clamps or pipes. Document location of any leaks.
13. Visually inspect the following components for leaks and note on repair order:

- | coolant pressure cap

- | core plugs

- | cylinder head gasket

- | engine block

- | intake manifold

- | radiator

- | thermostat housing

- | water pump

- | heater core and drain tube

14. Pressure test the cooling system. Using a black light and yellow lens glasses, inspect for coolant leaks (note location of any leaks on repair order). Were any leaks found?

• | Yes -- perform necessary repair to correct the concern. Proceed to Step 21.

• | No -- proceed with Step 15.

15. Inspect the radiator for any air flow obstructions or bent fins.
16. Inspect the engine coolant temperature (ECT) sensor terminals and the ECT harness connector for corrosion.
17. Inspect the engine coolant temperature (ECT) sensor for proper connector retention. Is the connector on, and is the lock tab engaged, or can the connector be slid off?
18. Inspect the following components for a gray/white milky substance:

- | engine oil fill cap

- | engine oil

- | transmission oil fluid level indictor (if equipped)

19. If no leak was found during the pressure test, it will be necessary to submit an oil sample to engineering for testing. Contact Brad Clark (248-857-2708) between 6:30 AM - 3:00 PM (EST) or Larry Szlachta (248-255-7649) after 3:00 PM EST to obtain an oil sample kit.

Important: If the call is not answered, please leave the technician name, dealer name, phone number, VIN and R.O. number. The engineer will respond within one hour of your call.

#### Oil Sample Procedure:

19.1. | Warm up the engine, then shut the engine off.

19.2. | Within 15 minutes of shut down, begin to drain the engine oil from the oil pan out of the drain plug.

19.3. | Allow the oil to start draining from the drain plug, then while the oil is still draining from the engine, collect a 3 oz. (89 ml) oil sample from the drain stream.

19.4. | Securely place the cap on the oil sample bottle.

19.5. | Complete the oil change for the customer.

19.6. | If equipped, be sure to reset the vehicle's Engine Oil Life System after the oil change is complete.

19.7. | Proceed with Step 20.

20. Mail the oil sample along with a copy of the front and back of the repair order, to:

General Motors Corporation

823 Joslyn Ave.

Pontiac, MI 48340-2920

Attn: Matthew Snider

Mailcode: 483-730-312

21. Fax the front and back of the repair order and any additional documentation/information observed according to the bulletin, to:

Attn: Brad Clark

Subject: L61 Coolant Loss

Fax #: 248-857-0748

### Warranty Information

Use the following labor operation to submit the warranty claim. Claim the appropriate add time based on repair made to correct the customer's concern. Note that for situations where the loss of coolant was caused by a leak, it will be necessary to refer to the Labor Time Guide to find the appropriate time to add to labor operation J7610.

Labor Operation | Description | Labor Time
--- | --- | ---
J7610* | Engineering Information -- Cooling System add: to repair cooling system leak add: To perform oil sample test | 0.8 hr
Add | To Repair Cooling System Leak | Refer to LTG for time based on repair made
Add | To Perform Oil Sample Test | 0.3 hr
* This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.