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Test E - Coolant Temperature Always Reads Cold

  1. Perform coolant temperature gauge test. See COOLANT TEMPERATURE GAUGE  under COMPONENT TESTING. If temperature gauge is okay, go to next step. On 1.8L, replace gauge if defective and retest system. On 1.9L, go to next step.
  2. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect instrument cluster connector C250 on vehicles without tachometer (C254 with tachometer) and temperature indicator sender unit connector. Measure resistance of Black/Orange wire between instrument cluster connector and temperature sender unit connector. If resistance is less than 5 ohms on 1.8L, go to next step. On 1.9L, replace temperature indicator sender unit and retest system. If resistance is more than 5 ohms, repair open in Black/Orange wire and retest system.
  3. Perform water temperature indicator sender test. See WATER TEMPERATURE INDICATOR SENDER UNIT under COMPONENT TESTING. If sender unit is okay, replace instrument cluster printed circuit and retest system. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If sender is bad, replace temperature indicator sender unit and retest system.
  4. Disconnect instrument cluster connector C250 on vehicles without tachometer (C254 with tachometer). Measure resistance of Black/Green wire between cluster connector and ground. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open in Black/Green wire and retest system.
  5. Disconnect cluster connector C250 on vehicles without tachometer (C254 with tachometer). Measure resistance between coolant temperature gauge clip "B" and coolant temperature gauge clip "S". Measure resistance between coolant temperature gauge clip "S" and coolant temperature gauge clip "G". If resistance is 190-232 ohms between "B" and "S", and 81-99 ohms between "S" and "G", replace instrument cluster printed circuit and retest system. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If resistances are not as specified, replace engine coolant temperature gauge and retest system.
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