23 · Diagnostics

Engine coolant leaks

Make: Fiat
Model: Panda Factory Service Manual
Year: 2003–2012
Section: Consumption /leaks/ wear › Engine coolant leaks

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Fault diagnosisEngine coolant leaks

ENGINE COOLANT LEAKS

A leak of engine coolant is seen with dripping and/or fouling of the engine

Versions with and without air conditioning.

1	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Carry out a visual inspect to locate the component or area which is leaking. If the visual inspection is not sufficient, wash the engine, dry it, start it and run it slowly until it comes up to temperature; to identify the leak, carry out a leak test on the system ( Op. 0510C30)	Continue to Step 2	Leak from the pipes	Continue to Step 3
			Leak from the radiator	Continue to Step 5
			Leak from the expansion tank	Continue to Step 6
			Leak from the water pump	Continue to Step 8
			Leak from the thermostat unit	Continue to Step 7
			Leak from the cylinder head	Continue to Step 9
			Leak from the heater radiator	Continue to Step 4
			Seepage of oil or water between the engine and the cooling circuit	Continue to Step 2
2	PRELIMINARY CHECKS	All OK	Problems met	Operation
	Check, in order, that the following are not present: Engine oil in the coolant. Water or emulsion in the engine oil.	Continue to Step 10	Oil in the engine coolant radiator	Continue to Step 9
			Emulsion or oil in the expansion tank	Continue to Step 9
			Emulsion or water in the engine oil sump	Continue to Step 11
3	PIPES CHECK	All OK	Problems met	Operation
	Check the condition and seal of the pipes. In particular: condition and correct fitting of the bands condition of hoses, connectors and plugs	End of diagnosis	Band tightening not correct.	Restore the correct tightening.
		End of diagnosis	Band tightening not correct.	Replace the components involved
4	HEATER CHECK	All OK	Problems met	Operation
	Check the condition of the heater radiator and relevant hoses and bands.	End of diagnosis	Heater radiator damaged, blocked, distorted.	Replace the radiator.
		End of diagnosis	Hoses and/or bands faulty	Replace the components involved Continue to Step 3
5	CHECK ON RADIATOR	All OK	Problems met	Operation
	Check the condition of the engine coolant radiator and relevant hoses and bands.	End of diagnosis	Radiator damaged, blocked, distorted	Replace the engine coolant radiator
		End of diagnosis	Radiator damaged, blocked, distorted	Continue to Step 3
6	CHECK EXPANSION TANK	All OK	Problems met	Operation
	Visually inspect: The condition of the expansion tank; The seal of the plug and breather valve.	End of diagnosis	Tank damaged or distorted.	Replace the reservoir
		End of diagnosis	Tank damaged or distorted.	Replace the cap
7	THERMOSTAT UNIT CHECK	All OK	Problems met	Operation
	Visually inspect: The condition of the thermostat unit; The seal of the gaskets	End of diagnosis	Thermostat group faulty	Replace the thermostat group
		End of diagnosis	Thermostat group faulty	Replace the gaskets.
8	CHECK ON WATER PUMP	All OK	Problems met	Operation
	Visually inspect: The condition of the water pump; The seal of the gaskets	End of diagnosis	Water pump faulty.	Replace the water pump.
		End of diagnosis	Gasket/s damaged	Replace the gaskets
9	CYLINDER HEAD COMPRESSION CHECK	All OK	Problems met	Operation
	Carry out the cylinder head compression test using the Examiner Op. 0520G15	Continue to Step 12	Cylinder head compression faulty	Replace the gasket and/or retighten correctly
10	CHECKING CYLINDER HEAD GASKET	All OK	Problems met	Operation
	Visually inspect: That the cylinder head tightening is correct; The seal of the gasket	Continue to Step 11	Cylinder head tightening not correct	Restore the correct tightening
		Continue to Step 11	Gasket damaged	Replace the seal
11	CYLINDER BLOCK/CRANKCASE PLANE CHECK	All OK	Problems met	Operation
	Remove the cylinder head. That that the following are absent: oily dross on the valves; defects in the cylinder block/crankcase plane; defects in the cylinder head gasket;	Continue to Step 12	Cylinder block/crankcase plane defective	Reface the cylinder block/crankcase
		Continue to Step 12	Presence of oily dross on the valves	Overhaul the cylinder head
12	Continue as instructed by the tester	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis	Fault persists	Continue to Step 1

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Parts & tools for this job Staging For 2003 Fiat Panda

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