Check for an incorrect or faulty radiator filler cap. Refer to Radiator Cap

Was an incorrect cap installed, or is the cap faulty?

--

Go to Step 2

Go to Step 3

Replace the filler cap.

Is there still a coolant loss?

103 kPa (15 psi)

Go to Step 3

System OK

Check for a leaking coolant recovery reservoir or reservoir hose.

Is the coolant recovery reservoir leaking, or is the reservoir hose leaking?

--

Go to Step 4

Go to Step 5

Replace the reservoir or the hose. Refer to Coolant Recovery Reservoir Replacement

Is there still a loss of coolant?

--

Go to Step 5

System OK

Check for any loose or damaged radiator hoses and connections.

Are any radiator hoses loose or damaged?

--

Go to Step 6

Go to Step 7

Re-seat the hoses and clamps. If necessary, replace the hoses and the clamps.

1. 3400 engine, refer to Radiator Hose Replacement or Radiator Hose Replacement

Is there still a coolant loss?

--

Go to Step 7

System OK

Check for a water pump gasket leak.

Is there a leak at the water pump gasket?

--

Go to Step 8

Go to Step 9

Replace the coolant pump gasket.

1. 3400 engine, refer to Water Pump Replacement

Is there still a coolant loss?

--

Go to Step 9

System OK

Check for a seal leak at the water pump.

Is there a leak at the water pump seal?

--

Go to Step 10

Go to Step 11

Replace the water pump.

1. 3400 engine, refer to Water Pump Replacement

Is there still a coolant loss?

--

Go to Step 11

System OK

Check if the cylinder head bolts are tightened to specification.

Are the cylinder head bolts tightened to the proper specification?

--

Go to Step 13

Go to Step 12

Tighten the cylinder head bolts to the proper specification. If necessary, replace the cylinder head gasket.

Is there still a coolant loss?

--

Go to Step 13

System OK

Check for any coolant leaks at the radiator. Refer to Radiator Leak Testing

Does the radiator have any leaks?

--

Go to Step 14

Go to Step 15

1. Inspect the radiator.
2. Replace the radiator as necessary. Refer to Radiator Replacement

Is there still a coolant loss?

--

Go to Step 15

System OK

1. Check the following for leaks:

•	The intake manifold

•	The engine block coolant drain hole plug

•	The heater core

Are any leaks occurring at any of these places?

--

Go to Step 16

System OK

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

Is there still a coolant loss?

--

--

System OK