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2002 V6 Mazda 626 Overheating

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Hi,

I think I may have narrowed down an Engine overheating problem to a leaky reservoir / overflow tank. It first manifested as A/C problems over the last couple weeks, really. I just assumed something was wrong with the design, where it didn't cool efficiently until you reached highway speeds, which would be enough to cool off the Engine so you could finally get good A/C. Finally last night the CEL comes on and honestly yesterday was the first time I noticed the Engine temp indicator was all the way on the HOT side, except when on the HWY it comes back to normal. I simply hadn't noticed. This morning I did some checks I read about -- debris in rad (can't really get rid of this without hose & water, besides being cooled off @ high speeds means it's clean enough, IMO), coolant level (below the low mark, I added more), and the state of the reservoir cap -- no rust, scale, etc.

But after I drove it for about ten minutes, the temp went all the way up again. When I came back and opened the hood, there was steam leaking from the side of the reservoir tank.

Question, should I C&D on driving the car till I can get a replacement tank put on? I may consider getting a rental but it'll cost me. Also, do generics typically work in these situations or should I wait on Mazda's? Finally, are there any other things I should be looking at? I also checked the upper and lower radiator hose pressure / temps to eliminate the thermostat as a cause of the problem. Lower hose was warm to the touch, not cool, so apparently the therm isn't stuck on closed. The top hose had some pressure and spring-back to it... I forget what this was supposed to eliminate... oh, water pump, I think it was. Let me know if I should pay attention to anything else. I will probably plan for a rental this morning but hopefully not much longer! I can't open the overflow tank for another three hours due to reaching Engine operating temp so I couldn't top off the coolant now even if I wanted, right? posted by  JaneiR36

Ugh. Dealer had the tank in stock. Apparently this is a common issue, the leaky reservoir. So I replaced the thing just now and took it out on a low-speed test drive. No more leaky from the overflow tank and the AC was actually cold for a while there. Then it went all the way to hot, just as I was about to do my victory dance

The lower hose I thought was warm is very much cold now. Pointing back to the thermostat, perhaps? But why not before? Why only now? Like I said, ugh. posted by  JaneiR36

My first impression is the expansion tank overflow is a symptom not a cause and that you have a knackered head gasket (you may be lucky with the thermostat replacement). You might find high engine temps are interlocked with the aircon operation to prevent the compressor from running. posted by  Wally

I just might have to jump off a cliff if you're right!! The therm really may not be it because it reports a nice low temp, until the Engine truly reaches operation speed then it turns to hot. If it was stuck, it really should read only one number with no rhyme or reason. Dang. posted by  JaneiR36

P0117 Engine coolant temperature circuit low input

Does this tend to point to anything in particular? I'll have the Sears folks look at it, buy probably not till tomorrow in case someone here is familiar with this and it's something simple :-) posted by  JaneiR36

Busted cooling fan relay. How embarassing! I tested the coil resistance and it was within spec. I should have just replaced it because there so cheap!! The dealer didn't have the relay in stock, so they replaced it with the defrost fan relay. Quite intelligent of them!! posted by  JaneiR36

Well done. I actually thought of that few days ago, but was too lazy to post. posted by  Wally