Engine Coolant Leak in or Around Spark Plug Well Area of Cylinder Head #01-T-47 - (Jan 7, 2003)

1998 - 2001 Saturn S-Series vehicles built up to and including VIN IZ3448617

Condition

Some customers may comment about one or more of the following:

• loss of engine coolant
• low coolant level
• Service Engine Soon Telltale illuminated
• low coolant telltale illuminated
• engine overheating
• engine misfire and/or engine runs rough

Cause

These conditions may be caused by an engine coolant leak at the spark plug well area due to minor porosity in cylinder head casting.

Correction

Add one 10 gram pellet of Engine Coolant System Sealer into the Coolant Recovery Reservoir.

For general information on the Engine Coolant System Sealer usage, refer to Technical Information Bulletin 97-T-40A.

Important

The Engine Coolant System Sealer and the following procedure is specifically approved for use in correcting only ineligible non-structural casting flaws which may occur on normal cylinder head castings at the spark plug well area. Coolant leaks at other locations should be corrected using other approved repair procedures. Never attempt to correct conditions other than the one specifically described in this bulletin with Engine Coolant System Sealer.

Procedure

Caution

DO NOT REMOVE THE CAP FROM A HOT SYSTEM. ALLOW THE SYSTEM TO COOL THEN SLOWLY REMOVE CAP.

1. Remove cap from coolant recovery reservoir.
2. Make sure tester and adapter are clean.




3. Install Coolant Tester Adapter SA9141E-2 to coolant recovery reservoir.

Important

The cooling system pressure test must be performed on a warm engine. The leak may not be found on a cold engine. The leak may not be found on a cold engine.

4. Start engine and operate until normal engine operating temperature is reached.
5. Turn engine off.
6. Remove spark plug wires from spark plugs.

Caution

WEAR SAFETY GOGGLES.

Caution

NEVER PRESSURIZE THE SYSTEM ABOVE 130 KPA (20 PSI).

7. Pump Tester until gauge needle reaches 103 kPa (15 psi).

Important

Over time, coolant leaks will generally leave a stain. With extended life coolant, this stain will usually be burnt or brownish orange in color.

Important

During the pressure test the leak observed may be very slight. Allow sufficient time for the coolant leak to be identified.

8. Inspect cylinder head for coolant leaks at each spark plug well area.
• If a coolant leak is not observed at any of spark plug well areas, refer to Cooling System Troubleshooting Chart in the Cooling section of the appropriate Engine Service manual for assistance in diagnosing and correcting other causes for the condition.
• If a coolant leak is observed at any spark plug well areas, proceed to next step.
  
  
  

  Caution

  DO NOT REMOVE THE TESTER ADAPTER FROM A HOT SYSTEM. ALLOW THE SYSTEM TO COOL THEN SLOWLY REMOVE TESTER ADAPTER.

9. Remove Coolant Tester Adapter SA9141E-2 from the coolant recovery reservoir.
10. Add one 10 gram pellet of Engine Cooling System Sealer into coolant recovery reservoir.




11. Install coolant recovery reservoir cap.
12. Install spark plug wires and retainers.
13. Start engine and operate until normal operating temperature is reached.
14. Continue to operate engine for an additional 10-15 minutes to allow sealer to be distributed to leak area.
15. Turn engine Off.
16. Verify that no leak exists.

Part Information

Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

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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