22 · Diagnostics

Engine coolant leaks

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Consumption /leaks/ wear › Engine coolant leaks

‹ Prev Engine coolant consumption Next › Engine oil leaks

Fault diagnosisEngine coolant leaks

ENGINE COOLANT LEAKS

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

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Preliminarily carry out a visual inspect to locate the component or area which is leaking. Check that there is no engine oil in the coolant. Check that there is no water or emulsion in the engine oil. If the visual inspection is not sufficient, wash the engine, dry it and let it slowly reach operating temperature. To identify the leak, if necessary, carry out a leak test on the system Op. Op. 0510C30 COOLING SYSTEM - TIGHTNESS TEST	End of diagnosis	Leak from the pipes	Continue to Step 1
			Leak from the radiator	Continue to Step 2
			Leak from the expansion tank	Continue to Step 3
			Leak from the water pump	Continue to Step 5
			Leak from the thermostat unit	Continue to Step 4
			Leak from the cylinder head	Continue to Step 6
			Leak from the heater radiator	Continue to Step 7
			Seepage of oil or water between the engine and the cooling circuit	Continue to Step 8
			Leak not located	Continue to Step 1
1	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	Continue to Step 2	Tightening not correct or components damaged	Restore the correct tightening or replace the components involved
2	CHECK ON RADIATOR	All OK	Problems met	Operation
3.2 V6	Check the condition of the radiator	Continue to Step 3	Radiator damaged or distorted	Replace the radiator Op. 1088B24
1.9 JTD 16V 2.0 JTS	Check the condition of the radiator	Continue to Step 3	Radiator damaged or distorted	Reaplce the radiator Op. Op. 1088B20 ENGINE COOLING RADIATOR - R + R
3	EXPANSION TANK CHECK	All OK	Problems met	Operation
	Visually inspect: The condition of the expansion tank; The seal of the plug Check the condition of the breather valve cap	Continue to Step 4	Tank damaged or distorted	Replace the tank Op. Op. 1088B10 ENGINE COOLING TANK - R + R or cap
4	THERMOSTAT UNIT CHECK	All OK	Problems met	Operation
	Visually inspect: The condition of the thermostat unit; The seal of the gaskets	Continue to Step 5	Thermostat group faulty	Replace the thermostat unit or the seals Op. Op. 1088C40 THERMOSTAT- R + R
5	CHECK ON WATER PUMP	All OK	Problems met	Operation
3.2 V6	Visually inspect: The condition of the water pump; The seal of the gaskets	Continue to Step 6	Water pump faulty	Replace the water pump or the gaskets Op. 1088C12
1.9 JTD 16V 2.0 JTS	Visually inspect: The condition of the water pump; The seal of the gaskets	Continue to Step 6	Water pump faulty	Replace the water pump or the gaskets Op. Op. 1088C10 WATER PUMP - R + R
6	CYLINDER HEAD GASKETS CHECK	All OK	Problems met	Operation
3.2 V6	Check: That the cylinder head tightening is correct; The gasket seal	Continue to Step 7	Cylinder head tightening not correct	Restore the correct tightening
3.2 V6		Continue to Step 7	Gasket damaged	Replace the seal Op. 1016D11
2.0 JTS	Check: That the cylinder head tightening is correct; The gasket seal	Continue to Step 7	Cylinder head tightening not correct	Restore the correct tightening
2.0 JTS		Continue to Step 7	Gasket damaged	Replace the seal Op. Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
1.9 JTD 16V	Check: That the cylinder head tightening is correct The gasket seal	Continue to Step 7	Cylinder head tightening not correct	Restore the correct tightening
1.9 JTD 16V		Continue to Step 7	Gasket damaged	Replace the seal Op. 1016B10
7	HEATER RADIATOR CHECK	All OK	Problems met	Operation
3.2 V6	Check the condition of the heater radiator	Continue to Step 8	Heater radiator damaged or distorted	Reaplce the radiator Op. 5040C54
1.9 JTD 16V 2.0 JTS	Check the condition of the heater radiator	Continue to Step 8	Heater radiator damaged or distorted	Reaplce the radiator Op. Op. 5040C50 AIR CONDITIONER HEATER RADIATOR - R+R
8	CYLINDER BLOCK/CRANKCASE PLANE CHECK	All OK	Problems met	Operation
3.2 V6	Remove the cylinder heads Op. 1016D11 Check that there are no: oily deposits on the valves; defects in the cylinder block/crankcase surface; defects in the cylinder head gasket;	Continue to Step 9	Cylinder block/crankcase plane defective	Reface the cylinder block/crankcase
3.2 V6		Continue to Step 9	Presence of oily dross on the valves	Overhaul the cylinder heads Op. Op. 1016E26 CYLINDER HEADS - OVERHAUL
1.9 JTD 16V 2.0 JTS	Remove the cylinder head Op. Op. 1016C10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL Check that there are no: oily deposits on the valves; defects in the cylinder block/crankcase surface; defects in the cylinder head gasket;	Continue to Step 9	Cylinder block/crankcase plane defective	Reface the cylinder block/crankcase
1.9 JTD 16V 2.0 JTS		Continue to Step 9	Presence of oily dross on the valves	Overhaul the cylinder head Op. Op. 1016E10 SINGLE CYLINDER HEAD, REMOVED - OVERHAUL
9	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis

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Parts & tools for this job For 2003 Alfa Romeo GT

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