07 Cooling System
07 Cooling System
07 Cooling System
DN
7-1
COOLING SYSTEM
TABLE OF CONTENTS
page
page
COOLANTADDING ADDITIONAL. . . . . . . . . . . 23
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . 23
COOLING SYSTEMDRAINING AND
FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COOLING SYSTEMCLEANING/REVERSE
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL AND INSTALLATION
COOLANT RESERVE/OVERFLOW TANK . . . . . . . 25
WATER PUMP5.2L/5.9L ENGINES . . . . . . . . . 25
WATER PUMP 4.7L ENGINES . . . . . . . . . . . . . . 27
WATER PUMP BYPASS HOSE5.2L/5.9L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
THERMOSTAT5.2L/5.9L ENGINE . . . . . . . . . . 32
THERMOSTAT 4.7L ENGINE . . . . . . . . . . . . . . 34
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 37
ACCESSORY DRIVE BELT5.2L/5.9L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ACCESSORY BELT REPLACEMENT4.7L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AUTOMATIC BELT TENSIONER5.2L/5.9L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
AUTOMATIC BELT TENSIONER4.7L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
RADIATOR DRAINCOCK . . . . . . . . . . . . . . . . . . . 40
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 41
CLEANING AND INSPECTION
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . 42
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SPECIFICATIONS
COOLING SYSTEM CAPACITIES. . . . . . . . . . . . . 43
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 44
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-2
COOLING SYSTEM
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OPERATION
The cooling system regulates engine operating temperature. It allows the engine to reach normal oper-
3 CROSSFLOW RADIATOR
COOLING SYSTEM
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7-3
LH CYL. HEAD
BLEED
THERMOSTAT LOCATION
RH CYL. HEAD
OPERATION
The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes
thermal expansion and contraction of coolant to keep
coolant free of trapped air. It provides a volume for
expansion and contraction of coolant. It also provides
a convenient and safe method for checking coolant
level and adjusting level at atmospheric pressure.
This is done without removing the radiator pressure
cap. The system also provides some reserve coolant
to the radiator to cover minor leaks and evaporation
or boiling losses.
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and
returned to a proper level in the radiator.
THERMOSTAT5.2L/5.9L ENGINES
DESCRIPTION
CAUTION: Do not operate an engine without a thermostat, except for servicing or testing.
The thermostat on all gas powered engines is
located beneath the thermostat housing at the front
of the intake manifold (Fig. 4).
The thermostat is a wax pellet driven, reverse poppet choke type.
Coolant leakage into the pellet container will cause
the thermostat to fail in the open position. Thermostats very rarely stick. Do not attempt to free a thermostat with a prying device.
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COOLING SYSTEM
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RADIATOR
WASHER FLUID RESERVOIR
COOLANT OVERFLOW/RESERVOIR
FAN SHROUD (UPPER)
SCREW
INTERLOCKING PINS
FAN SHROUD (LOWER)
The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance,
increased exhaust emissions and crankcase condensation that can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
THERMOSTAT4.7L ENGINE
DESCRIPTION
CAUTION: Do not operate an engine without a thermostat, except for servicing or testing.
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator. On all engines the
thermostat is closed below 195F (90C). Above this
temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall
temperature control. On the 4.7L engine the thermo-
Fig. 4 ThermostatTypical
1
2
3
4
5
THERMOSTAT HOUSING
GASKET
INTAKE MANIFOLD
THERMOSTAT
MACHINED GROOVE
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
COOLING SYSTEM
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7-5
FROM HEATER
FROM RADIATOR
TO WATER PUMP
ENGINE BYPASS
THERMOSTAT
higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a springloaded pressure relief valve. This valve opens when
system pressure reaches the release range of 124-to145 kPa (18-to-21 psi).
A rubber gasket seals the radiator filler neck. This
is done to maintain vacuum during coolant cool-down
and to prevent leakage when system is under pressure.
OPERATION
A vent valve in the center of the cap will remain
shut as long as the cooling system is pressurized. As
the coolant cools, it contracts and creates a vacuum
in cooling system. This causes the vacuum valve to
open and coolant in reserve/overflow tank to be
drawn through connecting hose into radiator. If the
vacuum valve is stuck shut, or overflow hose is
kinked, radiator hoses will collapse on cool-down.
RADIATOR
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and vertical plastic side tanks.
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radaitor core to cool the engine and
automatic transmission oil (if equipped).
WATER PUMP
DESCRIPTION
The water pump is located on the engine front
cover, and has an integral pulley attached (Fig. 8).
The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ventilation. The water pump seals are lubricated by
7-6
COOLING SYSTEM
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Fig. 7 RadiatorTypical
1 RADIATOR
2 A/C CONDENSER (IF EQUIPPED)
3 TRANSMISSION AUXILIARY OIL COOLER
OPERATION
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
FROM HEATER
FROM RADIATOR
TO WATER PUMP
ENGINE BYPASS
THERMOSTAT
OPERATION
When the thermostat is in the closed position the
bypass gallery is not obstructed allowing 100% flow.
When the thermostat is in the open position the stub
shaft enters the bypass gallery obstructing bypass
coolant flow by 50%. This design allows the coolant
to reach operating temperature quickly when cold,
while adding extra cooling during normal temperature operation.
COOLING SYSTEM
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7-7
OPERATION
When the thermostat is in the closed position the
bypass hose allows the water pump to circulate the
engine coolant through the cylinder block while at
the same time preventing the coolant from flowing
through the radiator, this allows the coolant to heat
up quicker thus bring the engine to operating temperature faster.
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COOLING SYSTEM
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The cord is attached to an engine compartment component with tie-straps. The heater is mounted in a
core hole of the engine cylinder block in place of a
freeze plug with the heating element immersed in
engine coolant.
OPERATION
OPERATION
HOSE CLAMPS
The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
DESCRIPTION
BLOCK HEATER
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An optional engine block heater is available for all
models. The heater is equipped with a power cord.
OPERATION
The worm type hose clamp uses a specified torque
value to maintain proper tension on a hose connection.
COOLING SYSTEM
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7-9
The spring type hose clamp applies constant tension on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
OPERATION
When sufficient heat is present, the viscous fan
drive will engage. This is when the air flowing
through the radiator core causes a reaction to the
bimetallic coil. It then increases fan speed to provide
the necessary additional engine cooling.
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.
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COOLING SYSTEM
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as
the following may be the cause:
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COOLING SYSTEM
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TEMPERATURE GAUGE
READS HIGH OR THE
COOLANT WARNING
LAMP ILLUMINATES.
COOLANT MAY OR MAY
NOT BE LOST OR
LEAKING FROM THE
COOLING SYSTEM
POSSIBLE CAUSES
CORRECTION
5. Tighten cap
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COOLING SYSTEM
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POSSIBLE CAUSES
7. Coolant level low in radiator but not
in coolant reserve/overflow tank. This
means the radiator is not drawing
coolant from the coolant reserve/
overflow tank as the engine cools
CORRECTION
7. (a) Check condition of radiator cap
and cap seals. Refer to Radiator Cap in
this Group. Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from the
radiator to the coolant tank. It should fit
tight at both ends without any kinks or
tears. Replace hose if necessary.
(d) Check coolant reserve/overflow tank
and tanks hoses for blockage. Repair as
necessary.
COOLING SYSTEM
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POSSIBLE CAUSES
CORRECTION
PRESSURE CAP IS
BLOWING OFF STEAM
AND/OR COOLANT TO
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW
TANK
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COOLING SYSTEM
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POSSIBLE CAUSES
CORRECTION
DETONATION OR
PRE-IGNITION (NOT
CAUSED BY IGNITION
SYSTEM). GAUGE MAY
OR MAY NOT BE
READING HIGH
1. Engine overheating.
HOSE OR HOSES
COLLAPSE WHILE
ENGINE IS RUNNING
NOISY VISCOUS
FAN/DRIVE
COOLING SYSTEM
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7 - 15
POSSIBLE CAUSES
CORRECTION
COOLANT COLOR
COOLANT LEVEL
CHANGES IN COOLANT
RESERVE/OVERFLOW
TANK. TEMPERATURE
GAUGE IS IN NORMAL
RANGE
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COOLING SYSTEM
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RADIATOR
ELECTRIC FAN ASSEMBLY
FAN SHROUD (LOWER)
SCREW
Test Procedure:
(1) Inspect 10A fuse in junction block and 40A
maxi fuse in PDC (Fig. 20).
(2) Remove Cooling Fan Relay from the PDC and
make the following checks at the relay connector:
Apply 12 volts (using a fused 14-gauge wire) to
circuit C25 (relay terminal 87). If fan does not come
on, check for open in circuit C25 or Z1. If circuits are
o.k., replace the cooling fan motor.
With the ignition key off check for battery voltage at circuit C28 (relay terminal 30). If no battery
voltage present check for open/shorted circuit C28
between the PDC and relay.
With the ignition key in the run position check
for battery voltage at circuit F18 (relay terminal 86).
If no battery voltage present, check for open/short in
circuit F18 between the junction block and the relay.
If no problems are detected, install the DRB
(refer to the appropriate Powertrain Diagnostic Procedures manual for DRB scan tool operating instructions) and start the engine. Clip a 12V test light to
the battery positive terminal and probe circuit C27
(relay terminal 85). When the engine temperature
reaches 110 C (230 F), or A/C is requested, the test
light should light. If not, check circuit C27 for open.
If no problems are detected at this point, replace
the cooling fan relay.
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COOLING SYSTEM
7 - 17
gauge pointer and determine condition of cooling system according to following criteria:
Holds Steady: If pointer remains steady for two
minutes, serious coolant leaks are not present in system. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or perform Internal Leakage Test.
Drops Slowly: Indicates a small leak or seepage
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly: Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
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COOLING SYSTEM
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cooling system, bubbles will appear in coolant. If bubbles do not appear, internal combustion gas leakage
is not present.
COOLING SYSTEM
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7 - 19
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory
drive pulleys for alignment, glazing, or excessive end
play.
POSSIBLE CAUSES
CORRECTION
2. Installation damage
2. Replace belt
1. Pulley misaligned
1. Align pulley(s)
2. Abrasive environment
3. Rusted pulley(s)
5. Replace belt
1. Inspect/Replace tensioner if
necessary
4. Replace belt.
BELT SLIPS
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COOLING SYSTEM
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9GROOVE JUMPING
(Belt does not maintain
correct position on pulley)
BELT BROKEN
(Note: Identify and correct
problem before new belt is
installed)
NOISE
(Objectionable squeal,
squeak, or rumble is heard
or felt while drive belt is in
operation)
TENSION SHEETING
FABRIC FAILURE
(Woven fabric on outside,
circumference of belt has
cracked or separated from
body of belt)
CORD EDGE FAILURE
(Tensile member exposed
at edges of belt or
separated from belt body)
POSSIBLE CAUSES
CORRECTION
1. Replace belt
2. Replace belt
1. Inspect/Replace tensioner if
necessary
2. Replace pulley(s)
4. Pulley misalignment
4. Align component
5. Replace belt
2. Replace belt
3. Severe misalignment
3. Align pulley(s)
1. Inspect/Replace tensioner if
necessary
2. Bearing noise
3. Belt misalignment
3. Align belt/pulley(s)
2. Replace belt
3. Replace belt
1. Inspect/Replace tensioner if
necessary
2. Replace belt
3. Replace pulley
4. Replace belt
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COOLING SYSTEM
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THERMOSTATGAS ENGINES
ON-BOARD DIAGNOSTICS
All gasoline powered models are equipped with
On-Board Diagnostics for certain cooling system components. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional information. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer to
the Diagnosis section of this group for other probable
causes. For other DTC numbers, refer to On-Board
Diagnostics in the General Diagnosis section of
Group 25, Emission Systems.
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diagnostic Procedures manual for diagnostic information
and operation of the DRB scan tool.
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COOLING SYSTEM
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COOLING SYSTEMDEAERATION
As the engine operates, any air trapped in cooling
system gathers under the radiator cap. The next time
the engine is operated, thermal expansion of coolant
will push any trapped air past radiator cap into the
coolant reserve/overflow tank. Here it escapes to the
atmosphere into the tank. When the engine cools
down the coolant, it will be drawn from the reserve/
overflow tank into the radiator to replace any
removed air.
RADIATOR
WASHER FLUID RESERVOIR
COOLANT OVERFLOW/RESERVOIR
FAN SHROUD (UPPER)
SCREW
INTERLOCKING PINS
FAN SHROUD (LOWER)
COOLANT SERVICE
For cooling system flush and fill maintenance
intervals, refer to Group 0, Lubrication and Maintenance.
COOLANT
SERVICE PROCEDURES
COOLANTROUTINE LEVEL CHECK
NOTE: Do not remove radiator cap for routine coolant level inspections. The coolant level can be
checked at coolant recovery bottle (Fig. 25).
The coolant reserve/overflow system provides a
quick method for determining coolant level without
removing radiator pressure cap. With engine not running, open the coolant recovery bottle cap and
remove coolant level indicator dipstick to observe
coolant level in coolant recovery bottle. The coolant
level should be between ADD and FULL marks. If
the coolant level is at or below the ADD mark, fill
the recovery bottle with a 50/50 mixture of antifreeze
and water ONE QUART AT A TIME. Repeat this procedure until the coolant level is at the FULL mark.
DESCRIPTION
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of
44 percent, year-round in all climates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
COOLING SYSTEM
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7 - 23
OPERATION
ETHYLENE-GLYCOL MIXTURES
Coolant flows through the engine block absorbing
the heat from the engine, then flows to the radiator
where the cooling fins in the radiator transfers the
heat from the coolant to the atmosphere. During cold
weather the ethylene-glycol coolant prevents water
present in the cooling system from freezing within
temperatures indicated by mixture ratio of coolant to
water.
COOLANTADDING ADDITIONAL
Do not remove radiator cap to add coolant to
system. When adding coolant to maintain correct
level, do so at coolant reserve/overflow tank. Use a
50/50 mixture of ethylene glycol antifreeze containing
Alugard 340-2 y and low mineral content water.
Remove radiator cap only for testing or when refilling system after service. Removing cap unnecessarily
can cause loss of coolant and allow air to enter system, which produces corrosion.
DRAINING
NOTE: On the 4.7L engine the thermostat is an inlet
side thermostat. This means that the engine coolant
will not drain when the radiator drain petcock is
opened. It will be necessary to remove the thermostat housing and thermostat to allow the coolant
traped in the engine block to drain.
(1) Remove radiator pressure cap.
(2) Loosen radiator petcock.
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COOLING SYSTEM
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COOLING SYSTEMCLEANING/REVERSE
FLUSHING
CLEANING
REVERSE FLUSHING
Reverse flushing of cooling system is the forcing of
water through the cooling system. This is done using
air pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty
systems with evidence of partial plugging.
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COOLING SYSTEM
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CHEMICAL CLEANING
In some instances, use a radiator cleaner (Mopar
Radiator Kleen or equivalent) before flushing. This
will soften scale and other deposits and aid flushing
operation.
CAUTION: Follow manufacturers instructions when
using these products.
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COOLING SYSTEM
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INSTALLATION
(1) Clean gasket mating surfaces.
(2) Using a new gasket, install water pump to
engine as follows: Guide water pump nipple into
bypass hose as pump is being installed. Install water
pump bolts. Tighten water pump mounting bolts to
40 Nm (30 ft. lbs.) torque.
(3) Position bypass hose clamp to bypass hose.
(4) Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
(5) Install a new O-ring to the heater hose coolant
return tube (Fig. 31). Coat the new O-ring with antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Fig. 31). Be sure the slot in tube
bracket is bottomed to mounting bolt. This will properly position return tube.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to coolant
return tube.
(9) Relax tension from belt tensioner (Fig. 30).
Install accessory drive belt.
COOLING SYSTEM
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7 - 27
CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If
not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 32) for correct
belt routing. The correct belt with correct length
must be used.
(10) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(11) Install fan shroud.
(12) Install fan blade/viscous fan drive assembly to
water pump shaft.
(13) Fill cooling system. Refer to Cooling System
Draining and Refilling in this group.
(14) Connect battery negative cable.
(15) Start and warm the engine. Check for leaks.
IDLER PULLEY
GENERATOR PULLEY
A/C COMPRESSOR PULLEY
IF W/OUT A/C
POWER STEERING PUMP PULLEY
WATER PUMP PULLEY
CRANKSHAFT PULLEY
AUTOMATIC TENSIONER
any of these conditions are found. Also check condition of the thermal viscous fan drive. Refer to Viscous
Fan Drive in this group.
The water pump can be removed without discharging the air conditioning system (if equipped).
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system. Refer to Draining Cooling System in this group.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) The thermal viscous fan drive is attached
(threaded) to the water pump hub shaft. Remove fan/
viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from
front. Threads on viscous fan drive are RIGHT
HAND. Using special tool spanner wrench 6958 with
adapter pins 8346 and a suitable fan wrench loosen
the fan drive (Fig. 33). Do not attempt to remove fan/
viscous fan drive assembly from vehicle at this time.
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COOLING SYSTEM
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1
2
3
4
5
6
7
RADIATOR
WASHER FLUID RESERVOIR
COOLANT OVERFLOW/RESERVOIR
FAN SHROUD (UPPER)
SCREW
INTERLOCKING PINS
FAN SHROUD (LOWER)
INSTALLATION
(1) Clean gasket mating surfaces.
(2) Using a new gasket, position water pump and
install mounting bolts as shown. (Fig. 36). Tighten
water pump mounting bolts to 54 Nm (40 ft. lbs.)
torque.
(3) Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
(4) Connect radiator lower hose to water pump.
(5) Relax tension from belt tensioner (Fig. 35).
Install drive belt.
COOLING SYSTEM
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CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 37) for correct belt
GENERATOR PULLEY
ACCESSORY DRIVE BELT
POWER STEERING PUMP PULLEY
CRANKSHAFT PULLEY
IDLER PULLEY
TENSIONER
A/C COMPRESSOR PULLEY
WATER PUMP PULLEY
(6) Position upper fan shroud and fan blade/viscous fan drive assembly.
(7) Be sure the upper and lower portions of the fan
shroud are firmly connected. All air must flow
through the radiator.
(8) Install two fan shroud-to-radiator screws (Fig.
34).
(9) Be sure of at least 25 mm (1.0 inches) between
tips of fan blades and fan shroud.
(10) Install fan blade/viscous fan drive assembly to
water pump shaft.
(11) Fill cooling system. Refer to Refilling the Cooling System in this group.
(12) Connect negative battery cable.
(13) Start and warm the engine. Check for leaks.
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COOLING SYSTEM
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INSTALLATION
(1) Position bypass hose clamps (Fig. 38) to center
of hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps (Fig. 38).
(4) Fill cooling system.
(5) Start and warm the engine. Check for leaks.
COOLING SYSTEM
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7 - 31
INSTALLATION
(1) Position bypass hose clamps to center of hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps (Fig. 38).
(4) Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2 (Fig.
40) to 54 Nm (40 ft. lbs.) torque. Tighten bolts (number 3 (Fig. 40) to 40 Nm (30 ft. lbs.) torque.
(5) Install a new O-ring to the heater hose coolant
return tube (Fig. 42). Coat the new O-ring with antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Fig. 42).
(7) Connect throttle body control cables.
(8) Install oil dipstick mounting bolt.
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COOLING SYSTEM
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THERMOSTAT5.2L/5.9L ENGINE
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
Factory installed thermostat housings on 5.2L/5.9L
engines are installed on a gasket with an anti-stick
coating. This will aid in gasket removal and clean-up.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is
below thermostat. Refer to Draining Cooling System
in this group.
(3) Air Conditioned vehicles: Remove support
bracket (generator mounting bracket-to-intake manifold) located near rear of generator (Fig. 44).
IDLER PULLEY
GENERATOR PULLEY
A/C COMPRESSOR PULLEY
IF W/OUT A/C
POWER STEERING PUMP PULLEY
WATER PUMP PULLEY
CRANKSHAFT PULLEY
AUTOMATIC TENSIONER
(4) On air conditioning equipped vehicles, the generator must be partially removed.
(a) Remove generator drive belt as follows: Drive
belts on 5.2L/5.9L engines are equipped with a
spring loaded automatic belt tensioner (Fig. 45).
(b) Attach a socket/wrench to pulley mounting
bolt of automatic tensioner (Fig. 45).
(c) Rotate tensioner assembly clockwise (as
viewed from front) until tension has been relieved
from belt.
(d) Remove belt from vehicle.
(e) Remove two generator mounting bolts. Do
not remove any wiring at generator. If equipped
COOLING SYSTEM
DN
7 - 33
1
2
3
4
5
THERMOSTAT HOUSING
GASKET
INTAKE MANIFOLD
THERMOSTAT
MACHINED GROOVE
INSTALLATION
(1) Clean mating areas of intake manifold and
thermostat housing.
(2) Install thermostat (spring side down) into
recessed machined groove on intake manifold (Fig.
46).
(3) Install gasket on intake manifold and over
thermostat (Fig. 46).
(4) Position thermostat housing to intake manifold.
Note the word FRONT stamped on housing (Fig. 47).
For adequate clearance, this must be placed towards
front of vehicle. The housing is slightly angled forward after installation to intake manifold.
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 Nm (200 in. lbs.) torque.
(6) Install upper radiator hose to thermostat housing.
(7) Air Conditioned vehicles:
CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If
not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 48) for correct
engine belt routing. The correct belt with correct
length must be used.
(a) Install generator. Tighten bolts to 41 Nm (30
ft. lbs.).
7 - 34
COOLING SYSTEM
DN
IDLER PULLEY
GENERATOR PULLEY
A/C COMPRESSOR PULLEY
IF W/OUT A/C
POWER STEERING PUMP PULLEY
WATER PUMP PULLEY
CRANKSHAFT PULLEY
AUTOMATIC TENSIONER
INSTALLATION
(1) Clean mating areas of timing chain cover and
thermostat housing.
(2) Install thermostat (spring side down) into
recessed machined groove on timing chain cover (Fig.
49).
(3) Position thermostat housing on timing chain
cover.
(4) Install two housing-to-timing chain cover bolts.
Tighten bolts to 13 Nm (115 in. lbs.) torque.
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
in timimg chain cover. If not, it may result in a
cracked housing, damaged timing chain cover
threads or coolant leaks.
COOLING SYSTEM
DN
7 - 35
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
(1) Disconnect battery negative cable.
(2) Drain cooling system. Refer to Draining and
Filling Cooling System in this section.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 50). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
7 - 36
COOLING SYSTEM
DN
RADIATOR
ELECTRIC COOLING FAN
UPPER SHROUD AND OVERFLOW BOTTLE
SCREW
LOWER SHROUD
INSTALLATION
The radiator has two isolator pins on bottom of
both tanks. These fit into alignment holes in radiator
lower support (Fig. 54).
(1) Position isolator pins into alignment holes in
radiator lower support.
(2) Install and tighten radiator mounting bolts to
23 Nm (200 in. lbs.) (Fig. 54).
(3) Install the transmission oil cooler lines, (if
equipped).
(4) Install front grille.
(5) Connect fan motor electrical connector to harness connector.
(6) Position upper fan shroud onto lower fan
shroud and radiator.
(7) Install retaining screws into shroud.
(8) Install radiator hoses. reconnect coolant
reserve/overflow tank hose.
(9) Connect battery negative cable.
COOLING SYSTEM
DN
7 - 37
CORE SUPPORT
LOWER ISOLATOR MOUNTS
ISOLATOR PINS
RADIATOR ASSEMBLY
SCREWS
BLOCK HEATER
REMOVAL
(1) Disconnect negative battery cable from battery.
(2) Drain coolant from radiator and cylinder block.
Refer to Draining Cooling System in this group.
(3) Remove power cord from block heater (Fig. 55).
(4) Loosen screw at center of block heater. Remove
heater assembly and o-ring seal.
INSTALLATION
(1) Thoroughly clean cylinder block core hole and
block heater seat.
(2) (all except 4.7L Engine). Position o-ring seal
on heater then insert block heater assembly with element loop pointing down (Fig. 55).
(3) 4.7L Engine Only, Insert block heater assembly with element loop pointing upward (12 Oclock)
(Fig. 56).
(4) With block heater fully seated, tighten center
screw to 2 Nm (17 in. lbs.) torque.
(5) Fill cooling system with recommended coolant.
Refer to Filling Cooling System section in this group.
(6) Start and warm the engine. Check for leaks.
7 - 38
COOLING SYSTEM
DN
INSTALLATION
CAUTION: When installing serpentine accessory
drive belt, the belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 58) for correct engine
belt routing. The correct belt with correct length
must be used.
(1) Position drive belt over all pulleys except idler
pulley. This pulley is located between generator and
A/C compressor.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 57).
(3) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place.
Remove wrench. Be sure belt is properly seated on
all pulleys.
(4) Check belt indexing marks. Refer to Automatic
Belt Tensioner5.2L/5.9L for more belt information.
TENSIONER
GENERATOR PULLEY
IDLER PULLEY
A/C COMPRESSOR PULLEY
WATER PUMP PULLEY
POWER STEERING PUMP PULLEY
CRANKSHAFT PULLEY
COOLING SYSTEM
DN
7 - 39
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAMAGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt tensioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts its stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 59).
GENERATOR PULLEY
ACCESSORY DRIVE BELT
POWER STEERING PUMP PULLEY
CRANKSHAFT PULLEY
IDLER PULLEY
TENSIONER
A/C COMPRESSOR PULLEY
WATER PUMP PULLEY
INSTALLATION
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt tensioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction (Fig. 59).
REMOVAL
(1) Remove accessory drive belt.
(2) Disconnect wiring and secondary cable from
ignition coil.
(3) Remove two mounting bolts and ignition coil
from engine (Fig. 61).
(4) Remove mounting bolt and tensioner assembly
from engine (Fig. 61).
WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(5) Remove pulley bolt. Remove pulley from tensioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 Nm (45 ft. lbs.).
(2) Position tensioner assembly and install mounting screw tighten screw to 67 Nm (50 ft. lbs.).
7 - 40
COOLING SYSTEM
DN
REMOVAL
(1) Remove accessory drive belt. Refer to Accessory
Drive Belt in this section.
(2) Remove tensioner assembly from mounting
bracket (Fig. 62).
WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pulley bolt. Remove pulley from tensioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 Nm (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
Nm (30 ft. lbs.).
(3) Install accessory drive belt.
(4) Check belt indexing marks.
RADIATOR DRAINCOCK
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
(1) Unscrew draincock stem (counterclockwise
rotation). When stem is completely unscrewed, pull it
from radiator tank and draincock body (Fig. 63).
COOLING SYSTEM
DN
7 - 41
INSTALLATION
(1) Install draincock stem loosely into body (Fig.
65). The draincock assembly cannot be installed if
stem is threaded into the body.
(2) Push draincock assembly into opening in radiator tank. It will snap into place when fully seated.
(3) Tighten draincock (clockwise) to 2.0 to 2.7 Nm
(18-25 in. lbs.) torque.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 68) to 23 Nm (17 ft. lbs.) torque.
(2) Position fan blade/viscous fan drive assembly
and upper shroud into vehicle.
7 - 42
COOLING SYSTEM
DN
1
2
3
4
5
RADIATOR
ELECTRIC COOLING FAN
UPPER SHROUD AND OVERFLOW BOTTLE
SCREW
LOWER SHROUD
RADIATOR CAP
CLEANING
Use only a mild soap and water to clean the radiator cap. Using any type solvent may cause damage
to the seal in the radiator cap.
COOLING SYSTEM
DN
7 - 43
INSPECTION
Hold cap at eye level, right side up. The vent valve
(Fig. 29) at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket,
replace cap. Do not use a replacement cap that
has a spring to hold vent shut. A replacement cap
must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.
RADIATOR
CLEANING
Clean radiator fins With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C condenser of debris.
INSPECTION
The radiator cooling fins should be checked for
damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.
WATER PUMP
CLEANING
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
SPECIFICATIONS
COOLING SYSTEM CAPACITIES
ENGINE
CAPACITY
5.2L/5.9L
4.7L
INSPECTION
FAN BLADE
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
7 - 44
COOLING SYSTEM
DN
SPECIFICATIONS (Continued)
COOLING SYSTEM
SPECIAL TOOLS
DESCRIPTION
Nm
Ft.
In.
Lbs.
Lbs.
67
50
(4.7L)
41
30
61
45
Block HeaterBolt
17
COOLING
Generator/Compressor
Mounting
BracketBolts
# 1 and 2
54
40
#3
40
30
50
23
17
Idler PulleyBolt
54
40
Radiator to SupportBolts
23
200
Thermostat HousingBolts
23
200
10
90
10
90
Water PumpBolts
40
30