Engine Coolant Leak in or Around Spark Plug Well Area of Cylinder Head

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

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

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.

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.

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