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1999 Jeep TJ Wrangler Service Manual - 07. Cooling System

1999 Jeep TJ Wrangler Service Manual - 07. Cooling System

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Published by bfranklin33
1999 Jeep TJ Wrangler Service Manual - 07. Cooling System
1999 Jeep TJ Wrangler Service Manual - 07. Cooling System

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Published by: bfranklin33 on Mar 07, 2010
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10/12/2012

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COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
ACCESSORYDRIVEBELTS ................ 3BLOCKHEATER ......................... 3COOLANT .............................. 2COOLINGSYSTEM ....................... 1COOLINGSYSTEM CIRCULATION ........... 2RADIATOR ............................. 2WATERPUMP .......................... 2
DESCRIPTION AND OPERATION
BLOCKHEATER ......................... 3COOLANTPERFORMANCE................. 4COOLANTRESERVE/OVERFLOWSYSTEM .... 3COOLANTSELECTIONANDADDITIVES ...... 4COOLINGSYSTEM HOSES................. 5RADIATORPRESSURECAP ................ 4THERMOSTAT ........................... 4TRANSMISSIONOIL COOLER .............. 3VISCOUSFANDRIVE ..................... 6WATERPUMP .......................... 5
DIAGNOSIS AND TESTING
ACCESSORYDRIVEBELTDIAGNOSIS........ 7COOLANT—LOWLEVEL AERATION ........ 19COOLINGSYSTEM DEAERATION........... 19COOLINGSYSTEM DIAGNOSIS ............ 10COOLINGSYSTEM—TESTINGFORLEAKS ... 16ON-BOARDDIAGNOSTICS(OBD) ........... 7PRELIMINARYCHECKS ................... 9RADIATORCAPTOFILLERNECKSEAL—PRESSURERELIEFCHECK .............. 18RADIATORCAP—PRESSURETESTING...... 19RADIATORCOOLANTFLOWCHECK ........ 16VISCOUSFANDRIVE .................... 17
SERVICE PROCEDURES
COOLANTLEVEL—ROUTINECHECK........ 19COOLANT—ADDINGADDITIONAL ......... 19COOLINGSYSTEM—DRAINING............ 20COOLINGSYSTEM—REFILLING ........... 20COOLINGSYSTEM—REVERSEFLUSHING ... 20SERVICECOOLANTLEVEL................ 20
REMOVAL AND INSTALLATION
ACCESSORYDRIVEBELT................. 27AUTOMATICTRANSMISSIONOIL COOLER... 21BLOCKHEATER ........................ 25COOLANTRESERVE/OVERFLOWBOTTLE .... 21RADIATOR ............................ 25THERMOSTAT .......................... 24VISCOUSFAN.......................... 26VISCOUSFANDRIVE .................... 27WATERPUMP ......................... 21
CLEANING AND INSPECTION
COOLINGSYSTEM ...................... 29COOLINGSYSTEM HOSES—INSPECTION ... 29FANBLADE............................ 29RADIATOR ............................ 28RADIATORPRESSURECAP ............... 28
ADJUSTMENTS
ACCESSORYDRIVEBELT................. 29
SPECIFICATIONS
ACCESSORYDRIVEBELTTENSION......... 30COOLINGSYSTEM CAPACITIES............ 30TORQUE .............................. 30
SPECIAL TOOLS
COOLING ............................. 31
GENERAL INFORMATION
COOLING SYSTEM
The cooling system is designed to maintain enginetemperature at an efficient level during all engineoperating conditions. Coolant circulation is controlledby the thermostat. The thermostat remains closeduntil the coolant reaches operating temperature. Thisprovides for fast engine warm up. When the enginereaches operating temperature, the thermostat opensand the coolant is circulated through the radiator tokeep the engine from overheating.The cooling system also provides a means of heat-ing the passenger compartment and cooling the auto-matic transmission fluid (if equipped). The coolingsystem is pressurized and uses a centrifugal waterpump to circulate coolant throughout the system.
TJ
COOLING SYSTEM 7 - 1
 
COMPONENTS
The components of the cooling system are:
A heavy duty radiator
Cooling fan (mechanical)
Thermal viscous fan drive
Fan shroud
Radiator pressure cap
Thermostat
Coolant reserve/overflow system
Automatic transmission oil cooler (internal toradiator)
Coolant
Water pump
Coolant hoses and clamps
COOLING SYSTEM CIRCULATION
For cooling system flow routings, refer to (Fig. 1)(Fig. 2).
WATER PUMP
A centrifugal water pump circulates coolantthrough the water jackets, passages, intake manifold,radiator core, cooling system hoses and heater core.The pump is driven from the engine crankshaft by adrive belt on all engines.
COOLANT
The cooling system is designed around the coolant.Coolant flows through the engine water jacketsabsorbing heat produced during engine operation.The coolant carries heat to the radiator and heatercore. Here it is transferred to the ambient air pass-ing through the radiator and heater core fins. Thecoolant also removes heat from the automatic trans-mission fluid in vehicles equipped with an automatictransmission.
RADIATOR
A heavy duty down-flow aluminum/plastic radiatoris used. The radiator consists of an aluminum coreand plastic end tanks, which are fastened to the corewith clinch tabs and sealed with a high temperaturerubber gasket. On automatic transmission equippedvehicles, the lower tank contains a concentric-tubetransmission oil cooler.
CAUTION: Plastic tanks, while stronger than brass,are subject to damage by impact, such aswrenches, mishandling, etc.
If the plastic tank has been damaged, individualparts are not available, and the radiator must bereplaced.
Fig. 1 Coolant Circulation—2.5L Engine 
7 - 2 COOLING SYSTEM
TJ
GENERAL INFORMATION (Continued)
 
ACCESSORY DRIVE BELTS
When installing an accessory drive belt, the beltMUST be routed correctly. If not, the engine mayoverheat due to water pump rotating in wrong direc-tion. Refer to the appropriate engine Belt Schematicin this group for the correct belt routing, or refer tothe Belt Routing Label located in the engine com-partment.
BLOCK HEATER
An optional engine block heater is available for allmodels. The heater is equipped with a power cord.The cord is attached to an engine compartment com-ponent with tie-straps. The heater warms the engineproviding easier engine starting and faster warm-upin low temperatures. The heater is mounted in a corehole of the engine cylinder block (in place of a freezeplug) with the heating element immersed in enginecoolant. Connect the power cord to a grounded 110-120 volt AC electrical outlet with a grounded, three-wire extension cord.
WARNING: DO NOT OPERATE ENGINE UNLESSBLOCK HEATER CORD HAS BEEN DISCONNECTEDFROM POWER SOURCE AND SECURED IN PLACE.
DESCRIPTION AND OPERATION
TRANSMISSION OIL COOLER
All models equipped with an automatic transmis-sion are equipped with a transmission oil cooler(water-to-oil) mounted internally within the radiatortank. This internal cooler is supplied as standardequipment on all models equipped with an automatictransmission.Transmission oil is cooled when it passes throughthis separate cooler. In case of a leak in the internalradiator mounted transmission oil cooler, engine cool-ant may become mixed with transmission fluid ortransmission fluid may enter the cooling system.Both cooling system and transmission should bedrained and inspected if the internal radiatormounted transmission cooler is leaking.These models do not come equipped with “auxilia-ry” transmission air-to-oil coolers.
COOLANT RESERVE/OVERFLOW SYSTEM
The system works along with the radiator pressurecap. This is done by using thermal expansion andcontraction of the coolant to keep the coolant free of trapped air. It provides:
A volume for coolant expansion and contraction.
A convenient and safe method for checking/ad- justing coolant level at atmospheric pressure. This isdone without removing the radiator pressure cap.
Some reserve coolant to the radiator to coverminor leaks and evaporation or boiling losses.As the engine cools, a vacuum is formed in thecooling system of both the radiator and engine. Cool-ant will then be drawn from the coolant tank andreturned to a proper level in the radiator.The coolant reserve/overflow system consists of aradiator mounted pressurized cap, a plastic coolantrecovery bottle (Fig. 3), a tube (hose) connecting theradiator and recovery bottle, and an overflow tube onthe side of the bottle.
BLOCK HEATER
The heater unit is mounted in a block core holeand is immersed in coolant. The heater uses ordinaryhouse current (110 Volt A.C.) and should
never
beplugged in unless it is immersed in coolant.
WARNING: DO NOT OPERATE ENGINE UNLESSBLOCK HEATER CORD HAS BEEN DISCONNECTEDFROM POWER SOURCE AND SECURED IN PLACE.
BLOCK HEATER SPECIFICATIONS
2.5L 4-Cylinder Engine: 115 Volts 400 Watts
4.0L 6-Cylinder Engine: 120 Volts 600 Watts
Fig. 2 Coolant Circulation—4.0L Engine 
TJ
COOLING SYSTEM 7 - 3
GENERAL INFORMATION (Continued)

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