Campaign - Poor Heater Output/Engine Overheat: Overview
08-097December 18, 2008
Applies To:
See VEHICLES AFFECTED
Product Update: Restricted Heater Core or Radiator Causes Poor Heating or Engine Overheating
(Supersedes 08-097, dated December 18, 2008, to update the information marked by the black bar or asterisks).
* BACKGROUND
Contamination in the factory fill engine coolant can eventually cause restrictions in the heater core and the radiator, leading to poor heater performance or, in rare cases, engine overheating.*
VEHICLES AFFECTED
Not all vehicles within the affected VIN ranges have contaminated coolant.
To verify vehicle eligibility, you must check at least one of these items:
^ The customer has a notification letter.
^ The vehicle is shown as eligible on a VIN status inquiry.
In addition, check for a punch mark above the first character of the engine compartment VIN. A punch mark in that location means this product update has already been completed.
Some of the vehicles affected by this product update may be in your used vehicle inventory. These vehicles should be updated before they are sold or leased.
CUSTOMER NOTIFICATION
All owners of affected vehicles will be sent a notification of this product update. An example of the customer notification is shown in this service bulletin.
CORRECTIVE ACTION
Inspect the engine coolant and, depending on the condition of the coolant and the heater core, do one of these repairs:
^ Replace the coolant.
^ Replace the radiator, the water bypass hoses, and the heater breather hose, and drain/refill the coolant.
^ Replace the radiator, the water bypass hoses, the heater breather hose, and the heater core, and drain/refill the coolant.
PARTS INFORMATION
REQUIRED MATERIALS
WARRANTY CLAIM INFORMATION
Failed Part: P/N 19010-PZD-A51
H/C 7272065
Defect Code: 5HE00
Symptom Code: Q9200
Skill Level: Repair Technican
INSPECTION PROCEDURE
1. Drain the engine coolant into a clean container:
^ Refer to page 10-6 of the 20032006 Element Service Manual, and do steps 1 thru 4, or
^ Online, enter keyword COOLANT, select Coolant Replacement from the list, and do steps 1 thru 4.
2. Check the clarity and the color of the drained coolant:
^ If the coolant is clear, and its color is bright blue or bright green, go to step 3.
^ If the coolant is cloudy, or if its color is not bright blue or bright green, go to REPAIR PROCEDURE.
3. Remove the radiator cap, and check for corrosion at the cap opening:
^ If there is no corrosion at the cap opening, go to step 4.
^ If you see corrosion at the cap opening, go to REPAIR PROCEDURE.
4. Add new coolant into the radiator:
^ Refer to page 10-7 of the service manual, and do steps 5 thru 12, or
^ Online, enter keyword COOLANT, select Coolant Replacement from the list, and do steps 5 thru 12.
5. Center-punch a completion mark above the first character of the engine compartment VIN.
REPAIR PROCEDURE
NOTE:
Do a VIN status inquiry to see if the heater core was already replaced. (It may have been replaced using Service Bulletin 07-076, Poor Heating Due to Restricted Heater Core.) If the heater core was replaced, do not do step 2.
1. Replace the radiator:
^ Refer to page 10-13 in the 2003-2006 Element Service Manual, and do steps 2 thru 9, or
^ Online, enter keyword RADIATOR, select Radiator and Fan Replacement from the list, and do steps 2 thru 9.
2. Replace the heater core:
^ Refer to page 21-43 in the service manual, or
^ Online, enter keywords HEATER UNIT, and select Heater Unit/Core Replacement from the list.
3. Replace the water bypass (RACV) inlet and outlet hoses and the heater breather hose.
4. Add about 1.5 gallons of coolant to the radiator, then install the radiator cap.
5. Start the engine, and let it reach normal operating temperature (the cooling fans cycle twice).
6. Shut the engine off, and open the radiator petcock one turn.
7. Monitor the cooling system pressure by lightly squeezing the upper radiator hose. Once the hose walls touch, remove the radiator cap and fully open the petcock. After the coolant is completely drained, tighten the petcock.
8. Add about 1.5 gallons of coolant to the radiator.
9. Start the engine, top off the coolant in the radiator if needed, then reinstall the radiator cap.
10. Let the engine idle for about 10 minutes.
11. Repeat steps 6 thru 10 two more times to remove any remaining contamination from the cooling system.
12. Tighten the radiator cap, then run the engine again and check for leaks.
13. Operate the heater, and make sure that warm air is coming from the vents.
14. Center-punch a completion mark above the first character of the engine compartment VIN.
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