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Tech Tip: Saturn's Slight Loss of Coolant/No External Leaks Evident Cheshire CT

Some customers may comment that the low coolant light is coming on and/or the coolant level is low with no external leaks visible. Low coolant may be accompanied by one of the following when the engine is cold. Read on to learn them.

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Tech Tip: Saturn's Slight Loss of Coolant/No External Leaks Evident

Models affected: 2003-’04 Saturn VUE and ION, and 2004 L300 vehicles with 2.2L engine (VINs D, F - RPO L61).

Some customers may comment that the low coolant light is coming on and/or the coolant level is low with no external leaks visible. Low coolant may be accompanied by one of the following when the engine is cold:
• engine being difficult to start;
• engine misfire for several seconds; or
• white smoke or coolant odor from the tailpipe.

This condition may be caused by porosity in the aluminum of the cylinder head casting.

Service Procedure
Diagnostic Checks
1. Verify the low coolant level.

2. Inspect all coolant hoses and connections for coolant leaks.

• If leaks are found, replace the hoses and/or tighten the clamps as necessary and return the vehicle to the customer.

• If no leaks are found, check the engine oil for signs of coolant contamination. Add black light dye (SA9176NE) to the cooling system and start the engine. Run the engine until it is at normal operating temperature 180° F (82° C) to allow the dye to circulate through the system.

3. Pressurize the cooling system to 25 psi (172 kpa) and monitor the gauge for pressure loss during the remaining inspections.

• Inspect all of the cooling system hoses and connections for visual signs of external leaks using the black light (J42220).

• Remove the spark plugs and inspect the threads for wetness from coolant and ch...

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