Engine overheat

Tiny
TIM HOANG
  • MEMBER
  • 1996 TOYOTA COROLLA
  • 1.6L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 115,000 MILES
Hi,

I have the car listed above BASE engine. The car had overheat problem. Temperature gauge indicated normal condition (middle between H and C) for a while. Then, it certainly raised to H (hot) in manner of minutes. Water was seen boiling from radiator water container. I noticed that the cooling fan did not run at that time. Issue is not seen during freeway driving.

I replaced thermostat and coolant temperature sensor but issue was still there.

Fuse for fan was good. I have located thermo fan switch. If I left ignition switch on (engine is off), and removed the connector from the thermo fan switch, the fan worked. The thermo fan switch is shown in the first picture.

I was about to replace this unit. But I ran into another article about different "fan sensor" located in the left side of the engine, below the exhaust manifold as in second picture (viewed and captured from YouTube video). I am not sure if second picture is applicable to my engine. It is not easy to reach.

Could you give me advice on what steps I should take to narrow down the problem in order to replace the right component?

Thanks,
-Tim
Saturday, February 24th, 2018 AT 7:26 PM

18 Replies

Tiny
TIM HOANG
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I just took a picture of second possible "fan sensor" in my car below the exhaust manifold. What is it called? Could you point me to the link of this part? Thanks,
-Tim
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Sunday, February 25th, 2018 AT 1:37 PM
Tiny
KEN L
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Hello,

The fan sensor is in the thermostat housing the one in the last picture is the coolant temperature sensor for the gauge i believe.

Here is a guide below that shows the sensor locations but I don't see the location in which you are showing here now.

My two cents is the cooling fans wont go on if you have a blown head gasket I would check there first here are two guides to help us find the problem and get it fixed.

https://www.2carpros.com/articles/head-gasket-blown-test

and

https://www.2carpros.com/articles/engine-overheating-or-running-hot

Please run down these guides and diagrams and report back

Cheers, Ken
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Wednesday, February 28th, 2018 AT 11:18 AM
Tiny
TIM HOANG
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Hi Ken,
Thank you for getting back to me. The fan is working but not trigger to run at when temperature is high; as such, I think it might be the fan sensor issue.

- I checked the 1st video: I don't see symptoms described in the video (coolant in engine). We have timing belt replaced in 2 years so gasket is supposed to be good.

- I reviewed 2nd video: it is very general. It also mentions about fan issue. It could be fan sensor.

The diagram does not include fan switch sensors. So, I am confused. What do you think?
Thanks,
-Tim
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Wednesday, February 28th, 2018 AT 7:32 PM
Tiny
KEN L
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Here is the cooling fan wiring diagrams you can see the two sensor/switches that work the system. If you ground the sensor wire at the thermostat housing with the key on the fan should run can you do this test please?

Check out the diagrams (Below)

Please let us know what happens.

Cheers, Ken
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Thursday, March 1st, 2018 AT 10:57 AM
Tiny
TIM HOANG
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Hi Ken,

Thank you. I edited the diagram and added in text to wire. Could you confirm that is the sensor wire you want me to try?

As I mentioned in the initial report, if I removed the socket out from sensor as in 2nd attached picture, the fan ran. The wire to this socket is "light green"
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Thursday, March 1st, 2018 AT 10:39 PM
Tiny
TIM HOANG
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(I hit wrong button)
. Here is attached edited diagram with 2 texts on "light green" wire: (1) and (2). Which one you want me to try?

I don't know if light green wire from my car (in previous picture) is (1) or (2). My best guess is that it is (1) as it is on engine block, far away from A/C unit.

Many thanks,
-Tim
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Thursday, March 1st, 2018 AT 10:42 PM
Tiny
KEN L
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The fan thermo switch is the one I would replace. You say once you remove the wire the fan runs correct?
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Friday, March 2nd, 2018 AT 10:14 AM
Tiny
TIM HOANG
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Yes, once I removed the wire, the fan ran. This is the switch I planed to buy and replace:

https://www.amazon.com/gp/product/B000CB3EQO/ref=ox_sc_act_title_1?smid=ATVPDKIKX0DER&psc=1

Thank you so much for your suggestion.
-Tim
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Friday, March 2nd, 2018 AT 12:05 PM
Tiny
KEN L
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Perfect let me know what happens. Cheers m8
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Friday, March 2nd, 2018 AT 2:11 PM
Tiny
TIM HOANG
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Ken, I have good and bad news.

I installed the new fan switch (from amazon order as above) and had OPD2 bluetooth readout to monitor temperature. Below was my findings:

1. Overheat issue was still not fixed.

2. As engine was running, the fan was kicked in when temperature reached 115C (above water boiling level). At that time, the temperature gauge already pointed to "H". As fan kicked in, temperature reduced down to 107C. Then, fan was switched off after that. As such temperature readout fluctuated a lot between 107 and 115.

3. If I turned off the engine (but still leave the key in the "ON" position), the fan stayed ON until temperature was below 100C (which was what we wanted).

From that experiment, the fan switch appears to work and fixes part of the problem. But something else interferes with the switch so that it is turned off at 107C. I fear that 2nd switch (picture posted on Sun 2/25) might need to be replaced but:
1. I don't know what it is called and how to find that part number.
2. I need to find another way to test if that switch is my problem.

From your posted diagram, there is also 2nd switch (AC high pressure switch). Is there anyway you can help narrow down to part number and its location for me?

Please let me know if you have any suggestions. Thanks,
-Tim
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Saturday, March 10th, 2018 AT 10:26 AM
Tiny
KEN L
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This is sounding more and more like you have a blown head gasket have you tested it?

https://www.2carpros.com/articles/head-gasket-blown-test
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Saturday, March 10th, 2018 AT 11:08 AM
Tiny
TIM HOANG
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From the article: when the gasket fails it can do so in five different ways.

1. Allowing coolant into the engine oil
2. Allow coolant to leak outside of the engine
3. Mix combustion gasses into the cooling system (radiator)
4. Allow combustion to transfer between two cylinders
5. Allow engine oil to leak outside of the engine

I reviewed paper. I do not have equipment to check for air pressure. But, I don't think it is gasket because:
1. Check oil fill cap --> do not see "milky goo" as shown in step 1
2. Check oil stick --> do not indication of water. I did change engine oil after we first ran into this issue. I did not notice water in the oil either when I put used oil in the recycle container
3. I let engine run with radiator cap off to observe coolant flow --> do not see water bubbles as in step 3.

Thanks,
-Tim
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Saturday, March 10th, 2018 AT 1:32 PM
Tiny
KEN L
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The chemical check is too check if you have exhaust gases present which can be the only sign of a blown head gasket and the over heating of course. You can get the kit from amazon

https://www.amazon.com/Block-Tester-BT-500-Combustion-Leak/dp/B06VVBSFTF/ref=sr_1_1_sspa?s=automotive&ie=UTF8&qid=1520878395&sr=1-1-spons&keywords=head+gasket+tester+kit&psc=1

to confirm.
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Monday, March 12th, 2018 AT 11:13 AM
Tiny
TIM HOANG
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Thanks. I will give it a try.
-Tim
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Monday, March 12th, 2018 AT 11:19 AM
Tiny
KHLOW2008
  • MECHANIC
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The cooling system works under pressurized conditions and you mentioned coolant boiling out of the reserve tank. This could mean a bad radiator cap. The other possible cause of the temperature going up high is poor coolant flow and could be due to partially clogged radiator or a weak water pump since you have already replaced the thermostat.
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Wednesday, March 14th, 2018 AT 8:53 AM
Tiny
TIM HOANG
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  • 11 POSTS
KHLOW,
Thank you for your feedback. It seemed much easier for me to try it out. I observed hot steam from the cap when coolant was boiling. But I did not realize important of the cap to hold pressure in the radiator. I have ordered the part today and hope for the best. Thanks,
-Tim
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Saturday, March 17th, 2018 AT 6:14 PM
Tiny
TIM HOANG
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Update from last message:
Changing the radiator cap did not solve the issue. I gave up and took the car to the shop. It turned out that rusted radiator is the source of the overheat issue. I changed the radiator fluid and flushed the radiator earlier but I could not get rid of the rusted color. It seemed that radiator was clogged due to rust.

That is a learning lesson for me. It cost $320.00 to fix. Thank you very much for suggestion.
-Tim
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Friday, April 20th, 2018 AT 8:58 AM
Tiny
KEN L
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Glad you could get it fixed, that kind of problem can be tough. Please use 2CarPros anytime we are here to help.

Cheers, Ken
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Friday, April 20th, 2018 AT 10:16 AM

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