ECT Sensor Related DTCs and/or the Following Condtions - Hard Start, Erratic Idle, Rough Running, Engine Overheating, Low and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated #01-T-07 - (Jan 7, 2003)

1991 - 2001 Saturn S-Series vehicles

Condition

Customers may comment about various driveability and/or engine operating concerns including: hard start, erratic idle, rough running, engine overheating, low and/or leaking coolant, and/or Service Engine Soon lamp illuminated.

Cause

This condition may be caused by a cracked engine coolant temperature sensor.

Correction

Replace engine coolant temperature sensor, inspect and if necessary replace sensor harness connector. Refer to procedure in this bulletin to replace engine coolant temperature sensor and Parts Requirements for specific parts information.

PROCEDURE

1. Disconnect engine coolant temperature sensor electrical connector and inspect sensor connector terminals for corrosion and/or evidence of engine coolant
• If terminals are corroded or if there is evidence of engine coolant, proceed to step 4.
• If terminals are not corroded and there is no evidence of engine coolant, reconnect the electrical connector and continue to next step.

  Caution

  TO AVOID THE DANGER OF BEING BURNED, DO NOT REMOVE THE CAP WHILE THE ENGINE, RADIATOR, AND SURGE TANK ARE STILL HOT. SCALDING FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE.

2. Perform one or both of the following checks to determine whether the engine coolant temperature sensor is providing the correct temperature indication.
• If engine is at ambient temperature (vehicle has been sitting overnight or not started for several hours), use a Scan tool to compare the inlet air temperature (IAT) to the engine coolant temperature (ECT). These two readings should be within 2° C (4°F) of each other.
• If engine is at operating temperature, install a thermometer in the coolant recovery reservoir. With the engine running and A/C off, use a Scan tool to compare the engine coolant temperature sensor reading to the thermometer reading. These two readings should be within 8° C (15° F) of each other. If engine coolant temperature sensor reading does not pass either of the above tests, continue with next step. If engine coolant temperature sensor reading passes both of the tests above, refer to appropriate symptom diagnostic chart in the Engine/Emissions Control Section of applicable Engine Service Manual.
3. Turn ignition Off.
4. Remove coolant surge tank cap.





Caution

DO NOT REMOVE CAP OR OPEN COOLING SYSTEM DRAINS FROM A HOT SYSTEM. ALLOW SYSTEM TO COOL FIRST.

5. Drain at least 1.9L (2 Qt.) of engine coolant from the cooling system by opening radiator drain valve or removing engine drain plug. Collect
6. Disconnect engine coolant temperature sensor electrical connector.
7. Remove engine coolant temperature sensor from cylinder head.
8. Obtain replacement engine coolant temperature sensor (P/N 21025106).
9. Use appropriate tap to clean sensor mounting hole of any thread sealant residue.
10. Install engine coolant temperature sensor in cylinder head.
Tighten

Engine Coolant Temperature Sensor: 8N·m (71 in lbs)

11. Inspect harness connector terminals for corrosion and/or evidence of engine coolant. If harness connector terminals are corroded or there is evidence of engine coolant. The harness connector must be replaced with new connector (P/N 12117087- includes : connector, terminals, wires, and splice sleeves).
12. Connect engine coolant temperature sensor connector.
13. Transfer engine coolant drained in step 5 into coolant surge tank. If necessary fill coolant surge tank to the FULL COLD range with 50/50 solution of correct type of antifreeze and clean water.
14. Start engine and check for leaks.
15. Run engine until upper radiator hose is hot, then add additional coolant if needed, to bring the level to the FULL COLD level (1991 -early 1997) or within the Min./Max. cold range (late 1997-2001).
16. Install coolant surge tank cap.

PARTS REQUIREMENTS

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer".  They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle.  Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely.  If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition.  See your GM dealer for information on whether your vehicle may benefit from the information.

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