GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 HVAC 🢒 HVAC - Manual 🢒 Loss of Coolant

Step

Action

Yes

No

DEFINITION: The cooling system is losing coolant either internally or externally.

1

Were you sent here from Symptoms or another diagnostic table?

Go to Step 2

Go to Symptoms - Engine Cooling

2

Repair any present DTCs. Refer to Diagnostic System Check - Vehicle.

Is the action complete?

Go to Step 3

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3

Inspect the coolant level.

Is the coolant at the proper level?

Go to Step 5

Go to Step 4

4

Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling.

Is the action complete?

Go to Step 5

--

5

If the engine is suspected to have a coolant leak into a cylinder, the coolant can hydraulically lock the engine.

Does the engine crankshaft rotate?

Go to Step 6

Go to Step 28

6

Engine overheating can cause a loss of coolant.

Is the engine overheating?

Go to Step 29

Go to Step 7

7

Extended operation with a low coolant level can cause engine internal component failure.

Is the engine knocking?

Go to Step 31

Go to Step 8

8
  1. Idle the engine at normal operating temperature.
  2. Inspect for heavy white smoke coming out of the exhaust pipe.

Is a heavy white smoke present from the exhaust pipe?

Go to Step 9

Go to Step 10

9
    • Coolant in the exhaust system creates a distinctive, burning coolant odor in the exhaust.
    • Condensation in the exhaust system can cause an odorless white smoke during engine warm up.

Does the white smoke have a burning coolant type odor?

Go to Step 30

Go to Step 10

10

Warning: Refer to Moving Parts and Hot Surfaces Warning in the Preface section.

With the engine idling, inspect the surge tank.

Does the surge tank discharge coolant while the engine is idling?

Go to Step 15

Go to Step 11

11

Visually inspect the hoses, pipes and hose clamps at the following locations:

    • Coolant surge tank
    • Heater core
    • Radiator

Are any of the hoses, clamps or pipes leaking?

Go to Step 22

Go to Step 12

12

Visually inspect the following components:

    • The coolant pressure cap
    • The core plugs
    • The cylinder head gaskets
    • The engine block
    • The intake manifold
    • The radiator
    • The thermostat housing
    • The water pump

Are any of the listed components leaking?

Go to Step 22

Go to Step 13

13
  1. Pressure test the cooling system. Refer to Cooling System Leak Testing.
  2. With the cooling system pressurized, visually inspect the components listed in steps 11 and 12.

Are any leaks present?

Go to Step 22

Go to Step 14

14

Pressure test the coolant pressure cap. Refer to Pressure Cap Testing.

Does the coolant pressure cap hold pressure?

Go to Step 16

Go to Step 23

15

Pressure test the coolant pressure cap. Refer to Pressure Cap Testing.

Does the coolant pressure cap hold pressure?

Go to Step 32

Go to Step 23

16

Inspect for the following conditions:

    • A coolant smell inside of the vehicle
    • Coolant in the HVAC module drain tube
    • Coolant on the vehicle floor covering near the HVAC module

Is coolant present?

Go to Step 24

Go to Step 17

17
  1. Add 30 ml (1 oz) of Extended Life Coolant Leak Detection Dye GM P/N 89022219 (Canadian P/N 89022220) to the cooling system for each 15 liters (4 gallons) of coolant. Refer to Approximate Fluid Capacities.
  2. Start the vehicle and allow the engine to reach normal operating temperature.
  3. Shut the engine off.
  4. Use J 42220 Universal 12V Leak Detection Lamp to visually inspect the components listed in steps 11 and 12.

Are any leaks present?

Go to Step 22

Go to Step 18

18

Use J 42220 to inspect for the following conditions:

    • Coolant dye in the HVAC module drain tube
    • Coolant dye on the vehicle floor covering near the HVAC module

Is coolant dye present?

Go to Step 24

Go to Step 19

19

Inspect the underside of the engine oil fill cap for a gray/white milky substance.

Is there a milky substance on under the oil fill cap?

Go to Step 20

Go to Step 21

20

Inspect the engine oil fluid level indicator for a gray/white milky substance.

Is there a milky substance on the engine oil fluid level indicator?

Go to Step 30

Go to Step 21

21

Inspect the automatic transmission oil fluid level indicator, if equipped, for a gray/white milky substance.

Is there a milky substance on the automatic transmission fluid level indicator?

Go to Step 25

Go to Step 33

22

Repair or replace the leaking component. Refer to the appropriate repair.

Is the repair complete?

Go to Step 33

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23

Replace the coolant pressure cap.

Is the repair complete?

Go to Step 33

--

24

Replace the heater core. Refer to Heater Core Replacement.

Is the repair complete?

Go to Step 33

--

25
  1. Remove the transmission oil cooler lines from the radiator.
  2. Pressure test the cooling system. Refer to Cooling System Leak Testing.
  3. Inspect the transmission oil cooler for coolant.

Is coolant present?

Go to Step 26

Go to Step 27

26
  1. Replace the radiator. Refer to Radiator Replacement.
  2. Service the automatic transmission. Refer to the appropriate procedure:
    3. •  Engine Coolant/Water in Transmission for the 4T45-E transaxle
    •  Engine Coolant/Water in Transmission for the 6T40/6T45 transmission
    •  Engine Coolant/Water in Transmission for the 6T70/6T75 transmission

Is the repair complete?

Go to Step 33

--

27

Install the cooler lines to the radiator.

Is the action complete?

Go to Step 33

--

28

Repair the engine no crank condition. Refer to the appropriate procedure:

    •  Engine Will Not Crank - Crankshaft Will Not Rotate for the 2.4L engine
    •  Engine Will Not Crank - Crankshaft Will Not Rotate for the 3.5L engine
    •  Engine Will Not Crank - Crankshaft Will Not Rotate for the 3.6L engine

Is the repair complete?

Go to Step 33

--

29

Repair the engine overheating condition. Refer to Engine Overheating.

Is the repair complete?

Go to Step 33

--

30

Repair the engine internal coolant leak. Refer to the appropriate procedure:

    •  Coolant in Combustion Chamber or Coolant in Engine Oil for the 2.4L engine
    •  Coolant in Combustion Chamber or Coolant in Engine Oil for the 3.5L engine
    •  Coolant in Combustion Chamber or Coolant in Engine Oil for the 3.6L engine

Is the repair complete?

Go to Step 33

--

31

Repair the engine knock. Refer to the appropriate procedure:

    •  Lower Engine Noise, Regardless of Engine Speed for the 2.4L engine
    •  Lower Engine Noise, Regardless of Engine Speed for the 3.5L engine
    •  Lower Engine Noise, Regardless of Engine Speed for the 3.6L engine

Is the repair complete?

Go to Step 33

--

32

Repair the combustion pressure in the cooling system problem. Refer to the appropriate procedure:

    •  Coolant in Combustion Chamber for the 2.4L engine
    •  Coolant in Combustion Chamber for the 3.5L engine
    •  Coolant in Combustion Chamber for the 3.6L engine

Is the repair complete?

Go to Step 33

--

33

Operate the system in order to verify the repair.

Did you find and correct the condition?

System OK

Go to Step 2