COOLING SYSTEM CONCERNS-OVERHEATING [SKYACTIV-D]

Troubleshooting item	COOLING SYSTEM CONCERNS-OVERHEATING
Description	• The engine coolant temperature is abnormally high.
Possible cause	• PCM DTC is stored. • Erratic signal to PCM ― ECT sensor or related circuit malfunction • A/C relay malfunction • Fan control module malfunction • Active air shutter actuator malfunction • Cooling system malfunction ― Active air shutter is fully-closed and does not operate ― There is foreign matter caught in active air shutter ― Cooling fan motor malfunction ― Coolant control valve malfunction ― Engine coolant passage (including radiator) malfunction (clogging, leakage)
System wiring diagram	• Not applicable
Connector diagram	• Not applicable

Troubleshooting item

COOLING SYSTEM CONCERNS-OVERHEATING

Description

• The engine coolant temperature is abnormally high.

Possible cause

• PCM DTC is stored.

• Erratic signal to PCM

― ECT sensor or related circuit malfunction

• A/C relay malfunction

• Fan control module malfunction

• Active air shutter actuator malfunction

• Cooling system malfunction

― Active air shutter is fully-closed and does not operate

― There is foreign matter caught in active air shutter

― Cooling fan motor malfunction

― Coolant control valve malfunction

― Engine coolant passage (including radiator) malfunction (clogging, leakage)

System wiring diagram

• Not applicable

Connector diagram

• Not applicable

Step	Inspection	Results	Action
1	VERIFY PCM DTC • Retrieve PCM DTCs using the M-MDS. (See DTC INSPECTION.) • Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-D)].)
No	Go to the next step.
2	VERIFY CURRENT INPUT SIGNAL STATUS Caution • While performing this step, always operate the vehicle in a safe and lawful manner. • When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later. • Access the following PID using the M-MDS: (See PID/DATA MONITOR TABLE [PCM (SKYACTIV-D)].) PCM ― ECT • Does the PID indicate the correct value under the trouble condition? (See PID/DATA MONITOR TABLE [PCM (SKYACTIV-D)].)	Yes	Inspect the related sensor and circuit. • If there is any malfunction: ― Repair or replace the malfunctioning part according to the inspection results, then go to Step 9. • If there is no malfunction: Vehicles with active air shutter ― Go to the next step. Vehicles without active air shutter ― Go to step 5.
No	Vehicles with active air shutter • Go to the next step. Vehicles without active air shutter • Go to step 5.
3	INSPECT ACTIVE AIR SHUTTER FOR MALFUNCTION • Inspect the applicable part. (See ACTIVE AIR SHUTTER INSPECTION.) • Is the part normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION.)
4	INSPECT ACTIVE AIR SHUTTER FOR OPERATION MALFUNCTION • Access the following simulation items using the M-MDS: (See SIMULATION INSPECTION.) PCM ― AIRSHUT_POS_COMD • Change to the following conditions using the simulation function. ― AIRSHUT_POS_COMD: 100 % • Access the AIRSHUT_POS_ACT PID using the M-MDS. (See PID/DATA MONITOR INSPECTION.) • Verify that the AIRSHUT_POS_ACT monitor value conforms to the AIRSHUT_POS_COMD monitor value when the simulation item AIRSHUT_POS_COMD is set from 0 % to 100 %.	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION.)
5	INSPECT A/C RELAY • Switch the ignition off. • Remove the A/C relay. • Inspect the A/C relay. (See RELAY INSPECTION.) • Is the A/C relay normal?	Yes	Go to the next step.
No	Replace the A/C relay, then go to repair completion verification.
6	INSPECT FAN CONTROL MODULE FOR MALFUNCTION • Inspect the applicable part. (See FAN CONTROL MODULE INSPECTION [SKYACTIV-D 1.8].) • Is the part normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
7	INSPECT COOLING FAN MOTOR FOR MALFUNCTION • Inspect the applicable part. (See COOLING FAN MOTOR INSPECTION [SKYACTIV-D 1.8].) • Is the part normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
8	DETERMINE IF MALFUNCTION CAUSE IS COOLANT CONTROL VALVE OR OTHER • Verify the radiator hose tension. Warning • To prevent burns, use a cloth with your hand to verify the tension of the radiator hose. • After the engine warms up, does the engine coolant circulate to the radiator hose?	Yes	Go to repair completion verification.
No	Go to the next step.
9	INSPECT COOLANT CONTROL VALVE FOR MALFUNCTION • Inspect the applicable part. (See COOLANT CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].) • Is the part normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
10	INSPECT SEALING OF ENGINE • Verify that there is no engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-D 1.8].) • Is the sealing of engine normal?	Yes	Inspect for clogging in the engine coolant passage. • If there is any malfunction: ― Repair or replace the malfunctioning part according to the inspection results, then go to the next step. • If there is no malfunction: ― Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results, then go to the next step.
Repair completion verification 1	VERIFY THAT VEHICLE IS REPAIRED • Install/connect the part removed/disconnected during the troubleshooting procedure. • Has the malfunction symptom been eliminated?	Yes	Complete the symptom troubleshooting. (Explain contents of repair to customer)
No	Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error. (See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].) • If the CAN communication is normal, perform the diagnosis from Step 1. ― If the malfunction recurs, go to the next step.
Repair completion verification 2	VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING • Verify repair information and verify that there is a new calibration in the PCM. • Is there a new calibration in the PCM?	Yes	Perform the PCM reprogramming and verify if the malfunction symptom was corrected. • If the malfunction recurs, replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
No	Replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Step

Inspection

Results

Action

VERIFY PCM DTC

• Retrieve PCM DTCs using the M-MDS.

(See DTC INSPECTION.)

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [PCM (SKYACTIV-D)].)

Go to the next step.

VERIFY CURRENT INPUT SIGNAL STATUS

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.

• Access the following PID using the M-MDS:

(See PID/DATA MONITOR TABLE [PCM (SKYACTIV-D)].)

PCM

― ECT

• Does the PID indicate the correct value under the trouble condition?

(See PID/DATA MONITOR TABLE [PCM (SKYACTIV-D)].)

Yes

Inspect the related sensor and circuit.

• If there is any malfunction:

― Repair or replace the malfunctioning part according to the inspection results, then go to Step 9.

• If there is no malfunction:

Vehicles with active air shutter

― Go to the next step.

Vehicles without active air shutter

― Go to step 5.

Vehicles with active air shutter

• Go to the next step.

Vehicles without active air shutter

• Go to step 5.

INSPECT ACTIVE AIR SHUTTER FOR MALFUNCTION

• Inspect the applicable part.

(See ACTIVE AIR SHUTTER INSPECTION.)

• Is the part normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION.)

INSPECT ACTIVE AIR SHUTTER FOR OPERATION MALFUNCTION

• Access the following simulation items using the M-MDS:

(See SIMULATION INSPECTION.)

PCM

― AIRSHUT_POS_COMD

• Change to the following conditions using the simulation function.

― AIRSHUT_POS_COMD: 100 %

• Access the AIRSHUT_POS_ACT PID using the M-MDS.

(See PID/DATA MONITOR INSPECTION.)

• Verify that the AIRSHUT_POS_ACT monitor value conforms to the AIRSHUT_POS_COMD monitor value when the simulation item AIRSHUT_POS_COMD is set from 0 % to 100 %.

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See ACTIVE AIR SHUTTER REMOVAL/INSTALLATION.)

INSPECT A/C RELAY

• Switch the ignition off.

• Remove the A/C relay.

• Inspect the A/C relay.

(See RELAY INSPECTION.)

• Is the A/C relay normal?

Yes

Go to the next step.

Replace the A/C relay, then go to repair completion verification.

INSPECT FAN CONTROL MODULE FOR MALFUNCTION

• Inspect the applicable part.

(See FAN CONTROL MODULE INSPECTION [SKYACTIV-D 1.8].)

• Is the part normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

INSPECT COOLING FAN MOTOR FOR MALFUNCTION

• Inspect the applicable part.

(See COOLING FAN MOTOR INSPECTION [SKYACTIV-D 1.8].)

• Is the part normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

DETERMINE IF MALFUNCTION CAUSE IS COOLANT CONTROL VALVE OR OTHER

• Verify the radiator hose tension.

Warning

• To prevent burns, use a cloth with your hand to verify the tension of the radiator hose.

• After the engine warms up, does the engine coolant circulate to the radiator hose?

Yes

Go to repair completion verification.

Go to the next step.

INSPECT COOLANT CONTROL VALVE FOR MALFUNCTION

• Inspect the applicable part.

(See COOLANT CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].)

• Is the part normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

INSPECT SEALING OF ENGINE

• Verify that there is no engine coolant leakage.

(See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-D 1.8].)

• Is the sealing of engine normal?

Yes

Inspect for clogging in the engine coolant passage.

• If there is any malfunction:

― Repair or replace the malfunctioning part according to the inspection results, then go to the next step.

• If there is no malfunction:

― Go to the next step.

Repair or replace the malfunctioning part according to the inspection results, then go to the next step.

Repair completion verification 1

VERIFY THAT VEHICLE IS REPAIRED

• Install/connect the part removed/disconnected during the troubleshooting procedure.

• Has the malfunction symptom been eliminated?

Yes

Complete the symptom troubleshooting. (Explain contents of repair to customer)

Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.

(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)

• If the CAN communication is normal, perform the diagnosis from Step 1.

― If the malfunction recurs, go to the next step.

Repair completion verification 2

VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING

• Verify repair information and verify that there is a new calibration in the PCM.

• Is there a new calibration in the PCM?

Yes

Perform the PCM reprogramming and verify if the malfunction symptom was corrected.

• If the malfunction recurs, replace the PCM.

(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Replace the PCM.

(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)