Temperature control systems can get out of control - A/C work fills the bays during the summer months. - Motor Age - Automotive training, certification & parts info

Service Repair

Temperature control systems can get out of controlA/C work fills the bays during the summer months.

Source: Motor Age




Since our world is driven and ruled by the three unbreakable Laws of Thermodynamics, it is foregone that extreme ambient temperatures will just about always bring customers and their vehicles in for unscheduled maintenance — work that isn't listed in those neat little owner's manual maintenance tables. Even though we still had frost-covered cars on some April mornings in Alabama and it snowed in North Dakota in June, the summer has been plenty warm enough to fill our service bays with temperature-related problems on both sides of the engine compartment bulkhead.

Warm weather notwithstanding, not all of the temperature-related problems we've dealt with are "too hot" problems; we've replaced faulty thermostats on four different vehicles that were running too cold over the past couple of weeks. The too hot problems tended to be HVAC concerns.

Too Cold, Too Hot, Too Smelly

The Dodge Stratus came to us with three primary concerns, and Ethan tackled the Malfunction Indicator Lamp (MIL) concern first. This was one of the two vehicles that week that threw us a P0128 code (coolant temperature below thermostat regulating temperature), and because the thermostat is so incredibly accessible on this Stratus (right under the radiator cap), we went there first and found that it had literally broken. A nice hot replacement thermostat warmed the engine up and neutralized the MIL in short order.


This thermostat gave way at some point and was unable to restrict coolant flow, thus the P0128 code.
Two of the four cold-running vehicles we did during the past two weeks illuminated their MILs and tossed P0128 codes that took us directly to the thermostat, because the PCM can't control emissions worth a darn unless the engine is running at about 200 degrees Fahrenheit.

Besides the emissions factor, a cold-running engine will eventually ruin itself because of the resulting sludge buildup and sulfuric acid production in the crankcase oil, not to mention the lost fuel economy from running in Open Loop (where the PCM ignores the O2 sensors). In the early part of a career that has spanned more than three decades now, I can remember a time when the cooling system thermostat was a lot more prone to be the cause of overheating problems rather than cold-running problems. But that has flip-flopped. When overheating does take place, the thermostat is still an item in question, and we've seen stuck closed thermostats in my department that wouldn't open even in a pan of boiling water – and we're pretty near sea level. It's really surprising how long a thermostat can last in the hostile environment where it lives.

The other two cold-running vehicles (a 2004 Trailblazer and my 2001 Cherokee) were noticed by the respective persons behind the wheel, but for whatever reason, the PCM didn't pick up on the problem on either vehicle. The Jeep was running only about 120 degrees Fahrenheit, and in spite of the fact that my thermostat seemed to work right in the hot water can, a new thermostat put my needle back on 200 degrees. Go figure.


The Stratus gave us these numbers even with a full charge. It was time for an expansion valve.
The next order of business on the 2004 Dodge Stratus was to diagnose the HVAC system — the unit seemed to cool tolerably well, but on the morning we were checking it, the ambient temperature was running about 70 degrees Fahrenheit. We identified the refrigerant as 100 percent R-134a and then connected a set of gauges to find that the pressures were ridiculously low across the board, actually pulling into the negative on the low side and running about 130 psi on the high side.


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Source: Motor Age,
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