Workshop Manuals Factory service & repair Fiat
Fiat Ulysse Factory Service Manual (2002-2010)22 · Fault diagnosis
22 · Diagnostics

Engine coolant leaks

Make
Fiat
Model
Ulysse Factory Service Manual
Year
2002–2010
Section
Consumption /leaks/ wear › Engine coolant leaks
Fault diagnosisEngine coolant leaks

ENGINE COOLANT LEAKS

2.0 16V JTD, 2.2 16V JTD · Additional heater

An engine coolant leak can be seen with consequent dripping and/or fouling of the engine.

STEPOPERATIONS TO BE CARRIED OUTTEST RESULTS
0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Carry out an initial visual inspection to locate the component that is leaking or the area of the leak.Check that there is no engine oil in the coolant. Check that there is no water or emulsion in the engine oil.Move on to Step1. Leak from the water pipesMove on to Step
2. Leak from the radiatorMove on to Step
3. Leak from the expansion tankMove on to Step
4. Leak from the water pumpMove on to Step
5. Leak from the thermostat unitMove on to Step
6. Leak from the heater radiatorMove on to Step
7. External leak from the cylinder headMove on to Step
8. Leak from the cylinder block/cylinder head plugs8. Replace the plugs
0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Carry out an initial visual inspection to locate the component that is leaking or the area of the leak.Check that there is no engine oil in the coolant. Check that there is no water or emulsion in the engine oil.Move on to Step1. Leak from the water pipesMove on to Step
2. Leak from the radiatorMove on to Step
3. Leak from the expansion tankMove on to Step
4. Leak from the water pumpMove on to Step
5. Leak from the thermostat unitMove on to Step
6. Leak from the additional heaterMove on to Step
7. Leak from the heater radiatorMove on to Step
8. External leak from the cylinder headMove on to Step
9. Leak from the cylinder block/cylinder head plugs9. Replace the plugs
1PIPE CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Check the condition of the pipes and the seal. More specifically:

  • the condition of the bands making sure they are correctly fitted;
  • the condition of the hoses, connectors and plugs
Move on to StepTightening not correct or components damagedRestore the correct tightening or replace the components involved
2RADIATOR CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check the condition of the radiatorMove on to StepRadiator damaged or distortedReplace the radiator
3EXPANSION TANK CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Visually check:

  • the condition of the expansion tank;
  • the seal of the cap

Check the condition of the cap breather valve

Move on to StepTank damaged or distorted

Replace the tank or the cap

Op. 1088B10 ENGINE COOLING TANK - R + R

4WATER PUMP CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Visually check:

  • the condition of the water pump;
  • the seal of the gaskets
Move on to StepWater pump faultyReplace the water pump or the gaskets
5THERMOSTAT UNIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Visually check:

  • the condition of the thermostat unit;
  • the seal of the gaskets
Move on to StepThermostat unit faulty

Replace the thermostat unit or the gaskets

Op. 1088C30 THERMOSTAT UNIT - R+R

6ADDITIONAL HEATER CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check the condition of the additional heater assemblyMove on to StepHeater damaged or distortedReplace the additional heater
7HEATER RADIATOR CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check the condition of the heater radiatorMove on to StepHeater radiator damaged or distortedReplace the heater radiator
8CYLINDER HEAD CHECKALL OKPROBLEMS ENCOUNTEREDACTION

Remove the head.Check:

  • Cylinder head plane correct planarity
  • Cylinder head support surface on cylinder block correct planarity;
Move on to Step1. Cylinder head plane defective1. Regrind the cylinder head plane
2. Cylinder block plane defective2. Regrind the cylinder block plane
3. Planes correct, head gasket faulty3. Change the head gasket
9CHECK ON CORRECT OPERATIONALL OKPROBLEMS ENCOUNTEREDACTION
Check that the fault is no longer present

Parts & tools for this job Staging For 2002 Fiat Ulysse

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