GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Malibu 🢒 Engine 🢒 Engine Cooling 🢒 Loss of Coolant

Step

Action

Yes

No

1

Were you sent here from SYMPTOMS?

Go to Step 2

Go to Symptoms - Engine Cooling in Engine Cooling

2

Repair any present DTC's. Refer to Diagnostic System Check - Engine Cooling .

Is the action complete?

Go to Step 3

--

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

Does the white smoke have a burning coolant type odor?

Go to Step 30

Go to Step 10

10

With the engine idling, inspect the coolant recovery system.

Does the coolant recovery system discharge coolant while the engine is idling?

Go to Step 15

Go to Step 11

11

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

    • Coolant reservoir
    • Heater
    • Radiator

Are any of the hoses, clamps or pipes leaking?

Go to Step 20

Go to Step 12

12

Visually inspect the following components:

    • Coolant pressure cap
    • Coolant reservoir
    • Core plugs
    • Cylinder head gaskets
    • Engine block
    • Intake manifold
    • Radiator
    • Thermostat
    • Water pump

Are any of the listed components leaking?

Go to Step 20

Go to Step 13

13
  1. Pressure test the cooling system. Refer to Cooling System Leak Testing .
  2. Visually inspect the components listed in steps 11 and 12 again.

Are any leaks present?

Go to Step 20

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 21

15

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

Does the coolant pressure cap hold pressure?

Go to Step 31

Go to Step 21

16

Inspect for the following conditions:

  1. A coolant smell inside of the vehicle.
  2. Coolant in the HVAC module drain tube.
  3. Coolant on the vehicles floor covering under the HVAC module.

Is coolant present?

Go to Step 22

Go to Step 17

17

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

Is there a milky substance under the oil fill cap?

Go to Step 18

Go to Step 19

18

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

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

Go to Step 23

Go to Step 19

19

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 26

Go to Step 32

20

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

Is the repair complete?

Go to Step 32

--

21

Replace the coolant pressure cap.

Is the repair complete?

Go to Step 32

--

22

Replace the heater core. Refer to Heater Core Replacement in HVAC.

Is the repair complete?

Go to Step 32

--

23
  1. Remove the engine oil cooler lines from the radiator.
  2. Pressure test the cooling system. Refer to Cooling System Leak Testing .
  3. Inspect the engine oil cooler for coolant.

Is coolant present in the engine oil cooler?

Go to Step 24

Go to Step 27

24
  1. Replace the radiator. Refer to Radiator Replacement .
  2. Service the engine oil and filter. Refer to Engine Oil and Oil Filter Replacement in Engine Mechanical.

Is the repair complete?

Go to Step 32

--

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 in the transmission oil cooler?

Go to Step 26

Go to Step 27

26
  1. Replace the radiator TRANS COOLER. Refer to Radiator Replacement .
  2. Service the automatic transmission. Refer to Engine Coolant/Water in Transmission in Automatic Transmission.

Is the repair complete?

Go to Step 32

--

27

Install the cooler lines to the radiator.

Is the repair complete?

Go to Step 32

--

28

Repair the engine no crank condition. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate in Engine Mechanical.

s the repair complete?

Go to Step 32

--

29

Repair the engine overheating condition. Refer to Engine Overheating .

Is the repair complete?

Go to Step 32

--

30

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

Is the repair complete?

Go to Step 32

--

31

Repair the engine knock. Refer to Lower Engine Noise, Regardless of Engine Speed in Engine Mechanical.

Is the repair complete?

Go to Step 32

--

32

Operate the system in order to verify the repair.

Does the system operate correctly?

System OK

Go to Step 2