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COOLING SYSTEM

TABLE OF CONTENTS
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DESCRIPTION AND OPERATION
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COOLANT PERFORMANCE. . . . . . . . . . . . . . . . . . 2
COOLANT RECOVERY SYSTEM. . . . . . . . . . . . . . 3
ENGINE THERMOSTAT. . . . . . . . . . . . . . . . . . . . . 3
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RADIATOR COOLING FAN MODULE. . . . . . . . . . . 3
COOLING SYSTEM PRESSURE CAP . . . . . . . . . . 4
RADIATOR HOSES AND CLAMPS . . . . . . . . . . . . 5
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AUTOMATIC TRANSMISSION OIL COOLER. . . . . 6
ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . . 6
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . . . 7
ENGINE THERMOSTAT TESTING . . . . . . . . . . . . 14
ACCESSORY DRIVE BELT DIAGNOSIS. . . . . . . . 14
WATER PUMP DIAGNOSIS . . . . . . . . . . . . . . . . 15
COOLING SYSTEM FLOW CHECK . . . . . . . . . . . 15
ELECTRIC FAN MOTOR TEST. . . . . . . . . . . . . . . 15
COOLANT CONCENTRATION TESTING. . . . . . . . 15
TESTING COOLING SYSTEM FOR LEAKS . . . . . 15
PRESSURE CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK . . . . . . . . . . . . . . . 16
PRESSURE TESTING COOLING SYSTEM
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . . 16
LOW COOLANT LEVEL AERATION. . . . . . . . . . . 17
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TEMPERATURE GAUGE INDICATION. . . . . . . . . 17
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 17
SERVICE PROCEDURES
COOLANT LEVEL CHECK—ROUTINE. . . . . . . . . 17
COOLANT—ADDING ADDITIONAL. . . . . . . . . . . 18
COOLANT LEVEL—SERVICING . . . . . . . . . . . . . 18
COOLING SYSTEM—DRAINING. . . . . . . . . . . . . 19
COOLING SYSTEM—REFILLING . . . . . . . . . . . . 19
REMOVAL AND INSTALLATION
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WATER PUMP INLET TUBE . . . . . . . . . . . . . . . . 20
ENGINE THERMOSTAT. . . . . . . . . . . . . . . . . . . . 20
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
RADIATOR DRAINCOCK. . . . . . . . . . . . . . . . . . . 22
COOLING FAN MODULE. . . . . . . . . . . . . . . . . . . 22
COOLANT RECOVERY CONTAINER . . . . . . . . . . 23
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 24
ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 24
AUTOMATIC BELT TENSIONER & PULLEY . . . . 26
DISASSEMBLY AND ASSEMBLY
COOLING FAN MODULE. . . . . . . . . . . . . . . . . . . 26
CLEANING AND INSPECTION
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ACCESSORY DRIVE BELT INSPECTION. . . . . . . 28
COOLING SYSTEM CAP . . . . . . . . . . . . . . . . . . . 28
COOLING SYSTEM CLEANING. . . . . . . . . . . . . . 28
RADIATOR FLUSHING . . . . . . . . . . . . . . . . . . . . 28
REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . . . 29
CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENTS
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIFICATIONS
COOLING SYSTEM CAPACITY . . . . . . . . . . . . . . 30
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 30
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION AND OPERATION
COOLING SYSTEM
The cool i ng system consi sts of an engi ne cool i ng
modul e, thermostat, cool ant, and a water pump to
ci rcul ate the cool ant. The engi ne cool i ng modul e may
consi st of a radi ator, el ectri c fan motor, fan, shroud,
cool ant reserve system, transmi ssi on oi l cool er, hoses,
cl amps, ai r condi ti oni ng condenser and transmi ssi on
oi l l i nes.
• When the Engi ne i s col d: The thermostat i s
cl osed and the cool i ng system has no fl ow through
the radi ator. The cool ant fl ows through the engi ne,
heater system and bypass.
• When the Engi ne i s warm: Thermostat i s open
and the cool i ng system has fl ow through the radi ator,
engi ne, heater system, and bypass.
PL COOLING SYSTEM 7 - 1
Cool ant fl ow ci rcui t for the 2.0L engi ne i s shown i n
(Fi g. 1).
Duri ng any reassembl y procedures al l pi pe fi tti ngs
i n water jacket, and water box requi re cl eani ng and
appl i cati on of thread seal ant for enti re l ength of
threads.
COOLANT
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne bl ock
metal and i n the cyl i nder head area near the exhaust
val ves. Then cool ant carri es thi s heat to the radi ator
where the tube/fi n assembl i es can gi ve off the heat to
the ai r.
Mopar௡ Anti freeze or the equi val ent i s recom-
mended for opti mum cool i ng performance and corro-
si on protecti on when mi xed to a freeze poi nt of -37° C
(-35° F).
COOLANT REPLACEMENT
Refer to Group 0, Lubri cati on and Mai ntenance for
schedul e.
COOLANT PERFORMANCE
Performance i s measurabl e. For heat transfer pure
water excel s (Formul a = 1 btu per mi nute for each
degree of temperature ri se for each pound of water).
Thi s formul a i s al tered when necessary addi ti ves to
control boi l i ng, freezi ng, and corrosi on are added as
fol l ows:
• Pure Water (1 btu) boi l s at 100°C (212°F) and
freezes at 0°C (32°F).
• 100 Percent Gl ycol (.7 btu) can cause a hot
engi ne and detonati on and wi l l rai se the freeze poi nt
to 22°C (-8°F).
• 50/50 Gl ycol and Water (0.82 btu) i s the recom-
mended combi nati on that provi des a freeze poi nt of
-37°C (-35°F). The radi ator, water pump, engi ne
water jacket, radi ator pressure cap, thermostat, tem-
perature gauge, sendi ng uni t and heater are al l
desi gned for 50/50 gl ycol .
Where requi red, a 56 percent gl ycol and 44 percent
water mi xture wi l l provi de a freeze poi nt of -59°C
(-50°F).
CAUTION: Richer mixtures cannot be measured
with field equipment which can lead to problems
associated with 100 percent glycol.
SELECTION AND ADDITIVES
The use of al umi num cyl i nder heads, i ntake mani -
fol ds, and water pumps requi res speci al corrosi on
Fig. 1 Cooling System Operation
1 – HEATER
2 – HEAT UP
3 – COOL DOWN
4 – PRESSURE CAP
5 – THERMOSTAT HOUSING
6 – WATER PUMP
7 – ENGINE
8 – COOLANT RECOVERY SYSTEM TANK
9 – RADIATOR
7 - 2 COOLING SYSTEM PL
DESCRIPTION AND OPERATION (Continued)
protecti on. Mopar௡ Anti freeze or the equi val ent i s
recommended for best engi ne cool i ng wi thout corro-
si on. When mi xed onl y to a freeze poi nt of -37°C
(-35°F) to -59°C (-50°F). I f i t l ooses col or or becomes
contami nated, drai n, fl ush, and repl ace wi th fresh
properl y mi xed sol uti on.
COOLANT RECOVERY SYSTEM
Thi s system works i n conjuncti on wi th the radi ator
pressure cap to uti l i ze thermal expansi on and con-
tracti on of the cool ant to keep the cool ant free of
trapped ai r. The system provi des space for expansi on
and contracti on. Al so, the system provi des a conve-
ni ent and safe method for checki ng and adjusti ng the
cool ant l evel at atmospheri c pressure wi thout remov-
i ng the pressure cap. I t al so provi des some reserve
cool ant to compensate for mi nor l eaks and evapora-
ti on or boi l i ng l osses. Al l vehi cl es are equi pped wi th
thi s system (Fi g. 2).
Refer to Cool ant Level Check, Deaerati on, and
Pressure Cap secti ons for operati on and servi ce.
ENGINE THERMOSTAT
The engi ne thermostat i s l ocated on the front of
the engi ne (radi ator si de) i n the thermostat housi ng/
engi ne outl et connector. The thermostat has an ai r
bl eed (vent) l ocated i n the fl ange and a O-ri ng for
seal i ng i ncorporate on i t. There i s a rel i ef i n the ther-
mostat housi ng/outl et connector for the O-ri ng.
The engi ne thermostat i s a wax pel l et dri ven,
reverse poppet choke type. I t i s desi gned to provi de
the fastest warm up possi bl e by preventi ng l eakage
through i t and to guarantee a mi ni mum engi ne oper-
ati ng temperature of 88 to 93°C (192 to 199°F). Al so,
the thermostat wi l l automati cal l y reach wi de open, to
accommodate unrestri cted fl ow to the radi ator as
temperature of the cool ant ri ses i n hot weather to
around 104°C (220°F). Above thi s temperature the
cool ant temperature i s control l ed by the radi ator, fan,
and ambi ent temperature—not the thermostat.
A thermostats pri mary purpose i s to mai ntai n
engi ne temperature i n a range that wi l l provi de sat-
i sfactory engi ne performance and emi ssi on l evel s
under al l expected dri vi ng condi ti ons. I t al so provi des
hot water (cool ant) for heater performance. I t does
thi s by transferri ng heat from engi ne metal and
automati c transmi ssi on oi l cool er (i f equi pped) to
cool ant, movi ng thi s heated cool ant to the heater core
and radi ator, and then transferri ng thi s heat to the
ambi ent ai r.
RADIATOR
The radi ator i s a down-fl ow type (verti cal tubes)
wi th desi gn features that provi de greater strength,
as wel l as suffi ci ent heat transfer capabi l i ti es to keep
the engi ne cool ant wi thi n operati ng temperatures.
The radi ator functi ons as a heat exchanger, usi ng
ai r fl ow across the exteri or of the radi ator tubes. Thi s
heat i s then transferred from the cool ant and i nto
the passi ng ai r.
The radi ator has an al umi num core wi th pl asti c
tanks. Al though stronger than brass, pl asti c tanks
are subject to damage by i mpact. Al ways handl e radi -
ator wi th care.
RADIATOR COOLING FAN MODULE
The radi ator cool i ng fan i s a si ngl e speed el ectri c
motor dri ven fan. The fan modul e i ncl udes an el ectri c
motor, fan bl ade, and a support shroud that i s
attached to the radi ator (Fi g. 3).
Fig. 2 Coolant Recovery System
1 – RECOVERY HOSE
2 – ENGINE COOLANT RECOVERY CONTAINER
3 – PRESSURE CAP
Fig. 3 Radiator Fan
1 – SCREWS
2 – LOWER MOUNTS
3 – FAN MOTOR ELECTRICAL CONNECTOR
PL COOLING SYSTEM 7 - 3
DESCRIPTION AND OPERATION (Continued)
Radi ator cool i ng fan control operati on i s accompl i shed
two ways. The fan al ways runs when the ai r condi ti on-
i ng compressor cl utch i s engaged. I n addi ti on to thi s
control , the fan i s turned on by the temperature of the
cool ant whi ch i s sensed by the cool ant temperature sen-
sor whi ch sends the message to the Powertrai n Control
Modul e (PCM). The PCM turns on the fan through a
fan rel ay by groundi ng the rel ay’s coi l . The fan rel ay i s
l ocated i n the Power Di stri buti on Center (PDC) (Fi g. 4).
Refer to the l abel beneath the PDC cover for l ocati on of
fan rel ay.
The PCM wi l l actuate the fan rel ay whenever the A/C
cl utch i s engaged regardl ess of cool ant temperature and
vehi cl e speed. I f the A/C cl utch i s not engaged, the PCM
wi l l actuate the fan rel ay when the cool ant temperature
reaches approxi matel y (97° C) 207° F and turns off the
fan rel ay when the cool ant temperature drops to
approxi matel y (94°C) 201° F. The fan rel ay i s al so
turned off when the vehi cl e speed i s above approxi -
matel y 100 Km/h (62 MPH). Refer to Group 8W, Wi ri ng
Di agrams for ci rcui ty provi ded.
I f the cool i ng fan i s i noperati ve or a Di agnosti c
Troubl e Code (DTC) rel ated to fan control has been
set, refer to the appropri ate Powertrai n Di agnosti c
Manual for compl ete di agnosti c procedures.
COOLING SYSTEM PRESSURE CAP
The cool i ng system pressure cap i s l ocated on the cool -
ant outl et housi ng near the front of the cyl i nder head.
The cool i ng system wi l l operate at hi gher than atmo-
spheri c pressure. The hi gher pressure rai ses the cool ant
boi l i ng poi nt, al l owi ng i ncreased radi ator cool i ng capac-
i ty. The pressure cap wi l l rel ease cool i ng system pres-
sure i n a range of 97–124 kPa (14–18 psi ).
A vent val ve l ocated i n the center of the cap al l ows
a smal l amount of cool ant fl ow from the cool ant
reserve system (CRS) tank. Thi s val ve i s spri ng
l oaded i n the cl osed posi ti on. However, i t must be
free to open duri ng system cool -down. If the valve is
stuck shut, the radiator hoses will collapse on
cool-down. Clean the vent valve (Fig. 5) to
ensure proper sealing function.
There i s a gasket i n the cap that seal s to the top of
the fi l l er neck so that vacuum i s mai ntai ned to draw
cool ant back i nto the system from the cool ant reserve
system (CRS) tank.
Fig. 4 Power Distribution Center (PDC)
RADIATOR COOLING FAN OPERATION CHART
Cooling Fan Control
A/C Off
Fan On: 97°C (207°F)
Fan Off: 94°C (201°F)
Vehicle Speed >
100 Km/h (62
MPH)
A/C On
Fan On—regardless of coolant temperature or vehicle
speed.
Fig. 5 Cooling System Pressure Cap
1 – PRESSURE RATING
2 – FILLER NECK SEAL
3 – PRESSURE VALVE
4 – VACUUM VENT VALVE (SHOWN IN SEALING POSITION)
7 - 4 COOLING SYSTEM PL
DESCRIPTION AND OPERATION (Continued)
RADIATOR HOSES AND CLAMPS
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE WORKING ON VEHI-
CLE. RELIEVE PRESSURE BY PLACING A SHOP
TOWEL OVER THE CAP AND WITHOUT PUSHING
DOWN ROTATE IT COUNTERCLOCKWISE TO THE
FIRST STOP. ALLOW FLUIDS TO ESCAPE
THROUGH THE OVERFLOW TUBE AND WHEN THE
SYSTEM STOPS PUSHING OUT COOLANT AND
STEAM AND THE PRESSURE DROPS CONTINUE
SERVICE.
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. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 6).
The hose cl amps are removed by usi ng Speci al Tool
6094 or equi val ent constant tensi on cl amp pl i ers
(Fi g. 7) to compress the hose cl amp.
A hardened, cracked, swol l en or restri cted hose
shoul d be repl aced. Care shoul d be taken not to dam-
age radi ator i nl et and outl et when removi ng hoses.
Radi ator hoses shoul d be routed wi thout any ki nks
and i ndexed as desi gned. The use of mol ded hoses i s
recommended.
Make sure hoses and connectors are cl ean and dry
before i nstal l ati on. Do not l ubri cate hoses when
i nstal l i ng.
Spri ng type hose cl amps are used i n al l appl i ca-
ti ons. I f repl acement i s necessary, repl ace wi th the
ori gi nal Mopar௡ equi pment spri ng type cl amp.
WATER PUMP
The water pump has a di ecast al umi num body and
housi ng wi th a stamped steel i mpel l er. The water
pump bol ts di rectl y to the cyl i nder bl ock and i s
dri ven by the ti mi ng bel t (Fi g. 8). Cyl i nder bl ock to
water pump seal i ng i s provi ded by a rubber O-ri ng.
The water pump i s the “heart” of the cool i ng sys-
tem. I t pumps the cool ant through the engi ne bl ock,
cyl i nder head, heater core, and radi ator.
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
Fig. 6 Spring Clamp Size Location
1 – SPRING CLAMP SIZE LOCATION
Fig. 7 Hose Clamp Tool
1 – HOSE CLAMP TOOL 6094
2 – HOSE CLAMP
Fig. 8 Water Pump
1 – CYLINDER BLOCK
2 – PUMP BODY
PL COOLING SYSTEM 7 - 5
DESCRIPTION AND OPERATION (Continued)
AUTOMATIC TRANSMISSION OIL COOLER
Oi l cool ers are i nternal oi l to cool ant type, mounted
i n the radi ator l ower tank (Fi g. 9). Rubber oi l l i nes
feed the oi l cool er and the automati c transmi ssi on.
Use onl y approved transmi ssi on oi l cool er hose. Si nce
these are mol ded to fi t space avai l abl e, mol ded hoses
are recommended. Ti ghten Oi l Cool er Hose Cl amps
to 2 N·m (18 i n. l bs.).
ACCESSORY DRIVE BELTS
The accessory dri ve consi st of two Pol y-V type
dri ve bel ts (Fi g. 10). One bel t dri ves the generator,
the other dri ves the power steeri ng pump and ai r
condi ti oni ng compressor (i f equi pped). The power
steeri ng/ai r condi ti oni ng bel t i s tensi oned by an auto-
mati cal l y control l ed bel t tensi oner. The generator
bel t i s manual l y tensi oned usi ng an adjusti ng bol t
and a l ocki ng nut.
ENGINE BLOCK HEATER
The heater i s mounted i n a core hol e (i n pl ace of a
core hol e pl ug) i n the engi ne bl ock, wi th the heati ng
el ement i mmersed i n cool ant (Fi g. 11). The engi ne
bl ock heater i s avai l abl e as an opti onal accessory.
The heater i s operated by ordi nary house current
(110 Vol t A. C.) through a power cord and connector
behi nd the radi ator gri l l e.
When i n operati on, the engi ne bl ock heater can
provi de easi er engi ne starti ng and faster warm-up,
when vehi cl e i s operated i n areas havi ng extremel y
l ow temperatures.
CAUTION: The power cord must be secured in its
retainer clips, and not positioned so it could con-
tact linkages or exhaust manifolds and become
damaged.
Fig. 9 Automatic Transmission Oil Cooler
1 – CLAMPS
2 – HOSES
Fig. 10 Accessory Drive Belts
1 – GENERATOR BELT
2 – AUTOMATIC BELT TENSIONER
3 – POWER STEERING PUMP/A/C COMPRESSOR BELT
Fig. 11 Engine Block Heater
1 – CORE PLUG
2 – BLOCK HEATER
3 – POWER CORD
7 - 6 COOLING SYSTEM PL
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
COOLING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open engine thermostat?
1. Refer to On Board Diagnostic in
Group 25. Replace thermostat, if
necessary. If a (DTC) has not been
set, the problem may be with the
temperature gauge.
2. Is the temperature gauge (if
equipped) connected to the
temperature gauge coolant sensor
on the engine?
2. Check the connector at the
engine coolant sensor. Refer to
Group 8E. Repair as necessary.
3. Is the temperature gauge (if
equipped) operating OK?
3. Check Gauge operation. Refer to
Group 8E. Repair as necessary.
4. Coolant level low during cold
ambient temperature, accompanied
by poor heater performance.
4. Check coolant level in the coolant
recovery/reserve container and the
radiator. Inspect the system for
leaks. Repair as necessary. Refer to
WARNINGS in this section before
removing pressure cap.
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST FROM SYSTEM.
1. Trailer being towed, a steep hill
being climbed, vehicle being
operated in slow moving traffic, or
engine idling during high ambient
(outside) temperatures with air
conditioning on. High altitudes
Could aggravate these conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and drive the vehicle
without any of the previous
conditions. Observe the temperature
gauge the gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause of the
overheating and repair. Refer to
POSSIBLE CAUSES in this section.
2. Is temperature gauge (if
equipped) reading correctly?
2. Check gauge. Refer to Group 8E.
Repair as necessary.
3. Is temperature warning lamp (if
equipped) illuminating
unnecessarily?
3. Check warning lamp operation.
Refer to Group 8E. Repair as
necessary.
4. Coolant low in recovery/reserve
container and radiator?
4. Check for coolant leaks and
repair as necessary. Refer to
Checking Cooling System for Leaks
in this section.
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.
5. Tighten cap.
PL COOLING SYSTEM 7 - 7
CONDITION POSSIBLE CAUSE CORRECTION
TEMPERATURE GAUGE READS
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST FROM SYSTEM. (CONT.)
6. Poor seals at radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator cap
Inspection. Replace cap if
necessary.
(b) Check condition of filler neck. If
neck is bent or damaged, replace
neck.
7. Coolant level low in radiator, but
not in coolant recovery/reserve
container. This indicates the
radiator is not drawing coolant from
the coolant recovery/reserve
container as the engine cools. As
the engine cools, a vacuum is
formed inside the cooling system. If
the radiator cap seals are defective,
or the cooling system has a leak, a
vacuum cannot be formed.
7. (a) Check condition of radiator
cap and cap seals. Replace cap if
necessary.
(b) Check condition of filler neck.
Replace if damaged.
(c) Check condition of hose from
filler neck to coolant container. It
should be tight at both ends without
any kinks or tears. Replace hose as
necessary.
(d) Check coolant recovery/reserve
container and hose for blockage.
Repair as necessary.
8. Freeze point of coolant not
correct. Mixture ratio may be too
rich.
8. Check coolant concentration.
Refer to Coolant Concentration
Testing in this section. Adjust
glycol-to-water ration as required.
9. Coolant not flowing through
system.
9. Check for coolant flow at filler
neck with some coolant removed,
engine warm, and thermostat open.
Coolant should be observed flowing
through filler neck. If flow is not
observed, determine reason for lack
of flow and repair as necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Clean obstruction from fins.
11. Radiator core is plugged or
corroded.
11. Replace or re-core radiator.
12. Fuel or ignition system
problems.
12. Refer to Fuel and Ignition
System groups for diagnosis. Also
refer to the appropriate Powertrain
Diagnostic Procedure manual.
13. Dragging Brakes. 13. Inspect brake system and repair
as necessary. Refer to Group 5,
Brakes for diagnosis.
14 Bug screen or other aftermarket
accessory is being used causing
reduced air flow.
14. Remove bug screen or
accessory.
15. Thermostat partially or
completely closed. This is more
prevalent on high mileage vehicles.
15. Check thermostat operation and
replace as necessary. Refer to
thermostat in this section for
procedure.
7 - 8 COOLING SYSTEM PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
16. Electric cooling fan not
operating properly.
16. Check electric fan operation and
repair as necessary.
17. Cylinder head gasket leaking. 17. Check cylinder head gasket for
leaks. Refer to testing cooling
system for leaks. For repairs, refer
to Group 9, Engine.
18. Heater core leaking. 18. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning and repair as
necessary.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
1. The gauge may cycle up and
down. This is due to the cycling of
the electric radiator fan.
1. A normal condition. No correction
is necessary. If gauge cycling is
going into the hot zone, check
electric fan operation and repair as
necessary. Refer to procedure in
this section.
2. During cold weather operation
with the heater blower in the high
position, the gauge reading may
drop slightly.
2. A normal condition. No correction
is necessary.
3, Temperature gauge or engine
mounted gauge sensor is defective
or shorted.
3. Check operation of gauge and
repair as necessary. Refer to Group
8E, Instrument Panel and Gauges.
4. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running).
4. A normal condition. No correction
is necessary. The gauge should
return to normal range after vehicle
is driven.
5. Gauge reading high after
restarting a warmed-up (hot)
engine.
5. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
6. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).
6. Check and correct coolant leaks.
Refer to Testing Cooling System For
Leaks in the section.
7. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system. This will cause
thermostat to open late.
7. (a) Check for cylinder head
gasket leaks with a commercially
available Block Leak Tester. Repair
as necessary.
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from exhaust system. Repair as
necessary.
8. Water pump impeller loose on
shaft.
8. Check water pump and replace
as necessary. Refer to Water Pump
in this section.
9. Loose drive belt (water pump
slipping).
9. Check drive belt and correct as
necessary.
PL COOLING SYSTEM 7 - 9
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
10. Air leak on the suction side of
water pump allows air to build up in
cooling system. This will cause the
thermostat to open late.
10. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
FLOWING INTO RECOVERY
CONTAINER. TEMPERATURE
GAUGE READING MAY BE ABOVE
NORMAL, BUT NOT HIGH.
COOLANT LEVEL MAY BE HIGH
IN RECOVERY CONTAINER.
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap
and seals. Refer to Radiator Cap in
this section. Replace as necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE IS
READING HIGH OR HOT.
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. Refer to Testing Cooling
System For Leaks in this section.
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH.
1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct.
2. Check the freeze point of the
coolant. Refer to Coolant
Concentration Testing in this
section. Adjust glycol-to-water ratio
as required.
HOSE OR HOSES COLLAPSE
WHEN ENGINE IS COOLING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
recovery/reserve container system.
1. (a) Radiator cap relief valve
stuck. Refer to Radiator Cap in this
section. Replace as necessary.
(b) Hose between coolant
recovery/reserve container and
radiator is kinked. Repair as
necessary.
(c) Vent at coolant recovery/reserve
container is plugged. Clean vent
and repair as necessary.
(d) Recovery/reserve container is
internally blocked or plugged. Check
for blockage and repair as
necessary.
ELECTRIC RADIATOR FAN
OPERATES ALL THE TIME.
1. Fan relay, powertrain control
module (PCM) or engine coolant
temperature sensor defective.
1. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
2. Check for low coolant level. 2. Repair as necessary.
7 - 10 COOLING SYSTEM PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
ELECTRIC RADIATOR FAN WILL
NOT OPERATE. GAUGE READING
HIGH OR HOT
1. Fan motor defective. 1. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
2. Fan relay, powertrain control
module (PCM) or engine coolant
temperature sensor defective.
2. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
3. Blown fuse in power distribution
center (PDC).
3. Determine reason for blown fuse
and repair as necessary.
NOISY FAN 1. Fan blade loose. 1. Replace fan blade assembly.
Refer to Cooling System Fan in this
section.
2. Fan blade striking a surrounding
object.
2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or A/C
condenser.
3. Remove obstructions and/or
clean debris from radiator and/or
A/C condenser.
4. Electric fan motor defective. 4. Refer to procedure in this section.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)
1. Radiator and/or air conditioning
condenser is restricted, obstructed
or dirty.
1. Remove restriction and/or clean
as necessary.
2. Electric radiator fan not operating
when A/C is on.
2. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
3. Engine is overheating (heat may
be transferred from radiator to A/C
condenser). High underhood
temperature due to engine
overheating may also transfer heat
to A/C components.
3. Correct overheating condition.
Refer to this section.
PL COOLING SYSTEM 7 - 11
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
INADEQUATE HEATER
PERFORMANCE.
1. Has a diagnostic trouble code
(DTC) been set?
1. Refer to On-Board Diagnostic in
Group 25, Emission Control
Systems.
2. Coolant level low. 2. Refer to testing cooling system
for leaks in this section. Repair as
necessary.
3. Obstructions in heater hose
fittings at engine.
3. Remove heater hoses at both
ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping
coolant to heater core. When the
engine is fully warmed up, both
heater hoses should be hot to the
touch. The water pump drive belt
may be slipping causing poor water
pump operation.
5. Refer to water pump in this
section. Repair as necessary.
HEAT ODOR 1. Various heat shields are used at
certain driveline components. One
or more of these shields may be
missing.
1. Locate missing shields and
replace or repair as necessary.
2. Is temperature gauge reading
above the normal range?
2. Refer to the previous
Temperature Gauge Reads High in
these Diagnostic Charts. Repair as
necessary.
3. Is cooling fan operating
correctly?
3. Refer to Cooling System Fan in
this section for diagnosis. Repair as
necessary.
4. Has undercoating been applied
to any unnecessary component.
4. Clean undercoating as necessary.
5. Engine may be running rich
causing the catalytic converter to
overheat.
5. Refer to appropriate Powertrain
Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
POOR DRIVEABILITY
(THERMOSTAT POSSIBLY STUCK
OPEN). GAUGE MAY BE READING
LOW
1. For proper driveability, good
vehicle emissions and for
preventing build-up of engine oil
sludge, the thermostat must be
operating properly. Has a diagnostic
trouble code (DTC ) been set?
1. Refer to On-Board Diagnostics in
Group 25, Emission Control
Systems. DTC’s may also be check
using the DRB scan tool. Refer to
the proper Powertrain Diagnostic
Procedure manual for checking the
thermostat if necessary.
7 - 12 COOLING SYSTEM PL
DIAGNOSIS AND TESTING (Continued)
CONDITION POSSIBLE CAUSE CORRECTION
STEAM IS COMING FROM FRONT
OF VEHICLE NEAR GRILL AREA
WHEN WEATHER IS WET,
ENGINE IS WARMED UP,
RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE.
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture contact
the hot radiator, steam may be
emitted. This usually occurs in cold
weather with no fan or airflow to
blow it away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. Check the freeze point of the
coolant. Refer to Coolant
Concentration Testing in this section
for procedure. Adjust the glycol-to-
water ratio as required.
COOLANT LEVEL CHANGES IN
COOLANT RECOVERY/RESERVE
CONTAINER
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the container was
between the FULL and ADD marks
at normal engine operating
temperature, the level should return
to within that range after operation
at elevated temperatures.
1. A normal condition. No repair is
necessary.
PL COOLING SYSTEM 7 - 13
DIAGNOSIS AND TESTING (Continued)
ENGINE THERMOSTAT TESTING
The thermostat i s operated by a wax fi l l ed con-
tai ner (pel l et) whi ch i s seal ed. When heated cool ant
reaches a predetermi ned temperature the wax pel l et
expands enough to overcome the cl osi ng spri ng and
water pump pressure, whi ch forces the val ve to open.
Cool ant l eakage i nto the pel l et wi l l cause a thermo-
stat to fai l open. Do not attempt to free up a thermo-
stat wi th a screwdri ver.
The thermostat that opens too soon type fai l ure
mode i s i ncl uded i n the on-board di agnosi s. The
check engi ne l i ght wi l l not be l i t by an open too soon
condi ti on. I f i t has fai l ed open, a di agnosti c troubl e
code (DTC) wi l l be set. Do not change a thermostat
for l ack of heater performance or temperature gauge
posi ti on, unl ess a DTC i s present. See Di agnosi s for
other probabl e causes. Thermostat fai l i ng shut i s the
normal l ong term mode of fai l ure, and normal l y, onl y
on hi gh mi l eage vehi cl es. The temperature gauge wi l l
i ndi cate thi s. Refer to Di agnosi s i n thi s secti on.
ACCESSORY DRIVE BELT DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
BELT SLIPPAGE 1. Belt slipping because of
insufficient tension.
1. Retension generator belt.
Replace the power steering belt’s
automatic belt tensioner.
2. Belt excessively glazed or
hardened from heat and excessive
slippage.
2. Replace belt.
3. Incorrect belt. 3. Replace belt.
4. Driven component bearing
failure.
4. Replace faulty component.
5. Belt or pulley subjected to
substance (belt dressing, oil,
ethylene glycol) that has reduced
friction.
5. Replace belt and clean pulleys.
BELT NOISE (OBJECTIONABLE
SQUEAL, SQUEAK, OR RUMBLE)
1. Belt slippage. 1. Retension generator belt, replace
belt, or automatic belt tensioner.
2. Foreign material imbedded in
belt.
2. Replace belt.
3. Non-uniform belt. 3. Replace belt.
4. Misaligned pulley(s). 4. Align accessories.
5. Non-uniform groove or eccentric
pulley.
5. Replace pulley(s).
6. Bearing noise. 6. Locate and repair.
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF
1. Broken cord in belt. 1. Replace belt.
2. Belt tension too loose, or too
tight.
2. Retension generator belt.
Replace the power steering belt’s
automatic belt tensioner.
3. Misaligned pulleys. 3. Align accessories.
4. Non-uniform grooves or eccentric
pulley.
4. Replace pulley(s).
5. Foreign object(s) in grooves. 5. Remove foreign objects in
groove.
7 - 14 COOLING SYSTEM PL
DIAGNOSIS AND TESTING (Continued)
WATER PUMP DIAGNOSIS
A qui ck fl ow test to tel l whether or not the pump i s
worki ng i s to see i f the heater warms properl y. A
defecti ve pump wi l l not be abl e to ci rcul ate heated
cool ant through the l ong heater hose.
Another fl ow test to hel p determi ne pump opera-
ti on:
WARNING: DO NOT remove radiator cap if the cool-
ing system is hot or under pressure.
(1) Remove cool i ng system pressure cap.
(2) Remove a smal l amount of cool ant from the
system.
(3) Start the engi ne and warm up unti l thermostat
opens.
(4) Wi th the thermostat open and cool ant l evel l ow,
vi sual l y i nspect for cool ant fl ow. I f fl ow i s present,
the water pump i s pumpi ng cool ant through the sys-
tem.
COOLING SYSTEM FLOW CHECK
To determi ne whether cool ant i s fl owi ng through
the cool i ng system, use the fol l owi ng procedures:
(1) I f engi ne i s col d, i dl e engi ne unti l normal oper-
ati ng temperature i s reached. Then feel the upper
radi ator hose. I f i t i s hot, cool ant i s ci rcul ati ng.
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
(2) Remove pressure cap when engi ne i s col d,
remove smal l amount of cool ant I dl e engi ne unti l
thermostat opens, you shoul d observe cool ant fl ow
whi l e l ooki ng down the fi l l er neck. Once fl ow i s
detected i nstal l the pressure cap.
ELECTRIC FAN MOTOR TEST
Refer to Powertrai n Di agnosti c Manual for proce-
dure.
COOLANT CONCENTRATION TESTING
Cool ant concentrati on shoul d be checked when any
addi ti onal cool ant was added to system or after a
cool ant drai n, fl ush and refi l l . The cool ant mi xture
offers opti mum engi ne cool i ng and protecti on agai nst
corrosi on when mi xed to a freeze poi nt of -37°C
(-34°F) to -59°C (-50°F). The use of a hydrometer or a
refractometer can be used to test cool ant concentra-
ti on.
A hydrometer wi l l test the amount of gl ycol i n a
mi xture by measuri ng the speci fi c gravi ty of the mi x-
ture. The hi gher the concentrati on of ethyl ene gl ycol ,
the l arger the number of bal l s that wi l l fl oat, and
hi gher the freeze protecti on (up to a maxi mum of
70% by vol ume gl ycol ).
A refractometer wi l l test the amount of gl ycol i n a
cool ant mi xture by measuri ng the amount a beam of
l i ght bends as i t passes through the fl ui d.
Some cool ant manufactures use other types of gl y-
col s i nto thei r cool ant formul ati ons. Propyl ene gl ycol
i s the most common new cool ant. However, propyl ene
gl ycol based cool ants do not provi de the same freez-
i ng protecti on and corrosi on protecti on and i s onl y
recommended for l i mi ted usage. Refer to appropri ate
Techni cal Servi ce Bul l eti n(s) regardi ng use of propy-
l ene gl ycol based cool ants.
CAUTION: Do not mix types of coolant—corrosion
protection will be severely reduced.
Because ethyl ene gl ycol and propyl ene gl ycol do
not have the same speci fi c gravi ti es, the use of a
hydrometer wi l l be i naccurate. Therefore, Speci al
Tool 8286 refractometer, i s recommended when test-
i ng ei ther ethyl ene or propyl ene gl ycol cool ants.
TESTING COOLING SYSTEM FOR LEAKS
The system shoul d be ful l . Wi th the engi ne not
runni ng, wi pe the fi l l er neck seal i ng seat cl ean.
Attach a radi ator pressure tester to the fi l l er neck,
as shown i n (Fi g. 12) and appl y 104 kPa (15 psi )
pressure. I f the pressure drops more than 2 psi i n 2
mi nutes, i nspect the system for external l eaks.
Move al l hoses at the radi ator and heater whi l e
system i s pressuri ze at 15 psi , si nce some l eaks occur
due to engi ne rock whi l e dri vi ng.
I f there are no external l eaks after the gauge di al
shows a drop i n pressure, detach the tester. Start the
engi ne, and run the engi ne to normal operati ng tem-
perature i n order to open the thermostat and al l ow
Fig. 12 Pressure Testing Cooling System—Typical
1 – PRESSURE TESTER
PL COOLING SYSTEM 7 - 15
DIAGNOSIS AND TESTING (Continued)
the cool ant to expand. Reattach the tester. I f the nee-
dl e on the di al fl uctuates i t i ndi cates a combusti on
l eak, usual l y a head gasket l eak.
WARNING: WITH THE PRESSURE TESTER IN
PLACE PRESSURE BUILDS UP QUICKLY. ANY
EXCESSIVE PRESSURE BUILD-UP DUE TO CON-
TINUOUS ENGINE OPERATION MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
I f the needl e on the di al does not fl uctuate, race
the engi ne a few ti mes. I f an abnormal amount of
cool ant or steam i s emi tted from the tai l pi pe, i t may
i ndi cate a faul ty head gasket, cracked engi ne bl ock,
or cracked cyl i nder head.
There may be i nternal l eaks, whi ch can be deter-
mi ned by removi ng the oi l di psti ck. I f water gl obul es
appear i ntermi xed wi th the oi l , i t i ndi cates an i nter-
nal l eak i n the engi ne. I f there i s an i nternal l eak,
the engi ne must be di sassembl ed for repai r.
PRESSURE CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal ) pressure
rel i ef can be checked by removi ng the overfl ow hose
at the radi ator fi l l er neck ni ppl e (Fi g. 13). Attach the
radi ator pressure tester to the filler neck nipple,
and pump ai r i nto the system. The pressure cap
upper gasket shoul d rel i eve pressure at 69-124 kPa
(10-18 psi ), and hol d pressure at 55 kPa (8 psi ) mi n-
i mum.
WARNING: THE WARNING WORDS DO NOT OPEN
HOT ON THE PRESSURE CAP IS A SAFETY PRE-
CAUTION. WHEN HOT, THE COOLING SYSTEM
BUILDS UP PRESSURE. TO PREVENT SCALDING
OR OTHER INJURY, THE PRESSURE CAP SHOULD
NOT BE REMOVED WHILE THE SYSTEM IS HOT
AND/OR UNDER PRESSURE.
There i s no need to remove the pressure cap at any
ti me except for the fol l owi ng purposes:
• Check and adjust cool ant freeze poi nt
• Refi l l system wi th new cool ant
• Conducti ng servi ce procedures
• Checki ng for l eaks
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP.
PLACE A SHOP TOWEL OVER THE CAP, AND WITH-
OUT PUSHING DOWN, ROTATE IT COUNTER-
CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS
TO ESCAPE THROUGH THE OVERFLOW TUBE.
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS, PUSH DOWN ON THE CAP AND REMOVE
IT COMPLETELY. SQUEEZING THE RADIATOR
INLET HOSE WITH A SHOP TOWEL (TO CHECK
PRESSURE) BEFORE AND AFTER TURNING TO
THE FIRST STOP IS RECOMMENDED.
PRESSURE TESTING COOLING SYSTEM
PRESSURE CAP
Di p the pressure cap i n water; cl ean off any depos-
i ts on the vent val ve or i ts seat, and appl y the cap to
end of radi ator pressure tester (Fi g. 14). Worki ng the
pl unger, i ncrease the pressure to 104 kPa (15 psi ) on
the gauge. I f the pressure cap fai l s to hol d pressure
of at l east 97 kPa (14 psi ), repl ace the cap.
Fig. 13 Cooling System Pressure Cap
1 – PRESSURE RATING
2 – FILLER NECK SEAL
3 – PRESSURE VALVE
4 – VACUUM VENT VALVE (SHOWN IN SEALING POSITION)
7 - 16 COOLING SYSTEM PL
DIAGNOSIS AND TESTING (Continued)
CAUTION: The radiator pressure tester is very sen-
sitive to small air leaks that will not cause cooling
system problems. A pressure cap that does not
have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to the tool. Turn the tool
upside down, and recheck the pressure cap to con-
firm that the cap is faulty.
If the pressure cap tests properly while posi-
tioned the on radiator pressure tester, but will not
hold pressure or vacuum when positioned on the
filler neck, inspect the filler neck and cap top gas-
ket for irregularities that may prevent the cap from
sealing properly.
LOW COOLANT LEVEL AERATION
• Wi l l cause corrosi on i n the system.
• Hi gh readi ng shown on the temperature gauge.
• Ai r i n the cool ant wi l l al so cause l oss of fl ow
through the heater.
• Exhaust gas l eaks i nto the cool ant can al so
cause the above probl ems.
DEAERATION
Ai r can onl y be removed from the system by gath-
eri ng under the pressure cap. On the next heat up i t
wi l l be pushed past the pressure cap i nto the cool ant
recovery contai ner by thermal expansi on of the cool -
ant. I t then escapes to the atmosphere i n the cool ant
recovery contai ner and i s repl aced wi th cool ant on
cool down.
TEMPERATURE GAUGE INDICATION
At i dl e the temperature gauge coul d ri se sl owl y to
about 1/2 gauge travel . The fan wi l l come on and the
gauge coul d drop to about 1/3 gauge travel , thi s i s
normal .
ENGINE BLOCK HEATER
I f heater uni t does not operate (Fi g. 15), possi bl e
causes can be ei ther the power cord or the heater el e-
ment. Test the power cord for conti nui ty wi th a 110-
vol t vol tmeter or 110-vol t test l i ght. Test heater
el ement conti nui ty wi th an ohmmeter or a 12-vol t
test l i ght.
CAUTION: To prevent damage, the power cord
must be secured in its retainer clips and away from
any components that may cause abrasion or dam-
age, such as linkages, exhaust components, etc.
SERVICE PROCEDURES
COOLANT LEVEL CHECK—ROUTINE
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The cool ant recovery/reserve system provi des a
qui ck vi sual method for determi ni ng the cool ant l evel
wi thout removi ng the radi ator cap. Si mpl y observe,
wi th the engi ne i dl i ng and warmed up to normal
operati ng temperature, that the l evel of the cool ant
i n the recovery/reserve contai ner (Fi g. 16) i s between
the FULL HOT and ADD marks.
Fig. 14 Pressure Testing Radiator Cap
1 – PRESSURE CAP
2 – PRESSURE TESTER
Fig. 15 Engine Block Heater
1 – CORE PLUG
2 – BLOCK HEATER
3 – POWER CORD
PL COOLING SYSTEM 7 - 17
DIAGNOSIS AND TESTING (Continued)
COOLANT—ADDING ADDITIONAL
NOTE: The radiator cap should not be removed.
When addi ti onal cool ant i s needed, i t shoul d be
added to the cool ant recovery/reserve contai ner (Fi g.
17). Use onl y 50/50 concentrati on of ethyl ene gl ycol
type anti freeze and water
COOLANT LEVEL—SERVICING
NOTE: The cooling system is closed and designed
to maintain coolant level to the top of the radiator.
When servi ci ng requi res a cool ant l evel check i n
the radi ator, the engi ne must be off and not under
pressure. Drai n several ounces of cool ant from the
radi ator drai n cock whi l e observi ng the Cool ant
Recovery Contai ner. Cool ant l evel i n the contai ner
shoul d drop sl i ghtl y. Then remove the radi ator cap,
(Fi g. 17). The radi ator shoul d be ful l to the top. I f
not, and the cool ant l evel i n the recovery contai ner i s
at the ADD mark there i s a ai r l eak i n the recovery
system. Check hose or hose connecti ons to the recov-
ery contai ner, radi ator fi l l er neck or the pressure cap
seal to the radi ator fi l l er neck for l eaks.
Fig. 17 Coolant Recovery Container and Pressure Cap Locations
1 – ENGINE OIL FILL
2 – ENGINE COOLANT RECOVERY CONTAINER
3 – ENGINE OIL DIPSTICK
4 – COOLING SYSTEM PRESSURE CAP
Fig. 16 Coolant Level
1 – COOLANT RECOVERY CONTAINER
7 - 18 COOLING SYSTEM PL
SERVICE PROCEDURES (Continued)
COOLING SYSTEM—DRAINING
NOTE: Drain, flush, and fill the cooling system at
the mileage or time intervals specified in Group 0,
Lubrication and Maintenance. If the solution is dirty,
rusty, or contains a considerable amount of sedi-
ment; clean and flush with a reliable cooling system
cleaner. Care should be taken in disposing of the
used engine coolant from your vehicle. Check gov-
ernmental regulations for disposal of used engine
coolant.
Without removing radiator pressure cap and
with system not under pressure:
(1) Shut engi ne off and turn drai ncock counter-
cl ockwi se to open (Fi g. 18).
(2) The cool ant reserve tank shoul d empty fi rst,
then remove the pressure cap. (i f not, Refer to Test-
i ng Cool i ng System for l eaks).
COOLING SYSTEM—REFILLING
Fi rst cl ean system to remove ol d gl ycol , see Cool i ng
System Cl eani ng.
Fi l l system wi th 50/50 gl ycol /water mi x. Use anti -
freeze descri bed i n Cool ant secti on.
Conti nue fi l l i ng system unti l ful l , thi s provi des bet-
ter heater performance. Be careful not to spill
coolant on drive belts or the generator.
Fi l l cool ant reserve/recovery system to at l east the
FULL HOT mark wi th 50/50 sol uti on. I t may be nec-
essary to add cool ant to the reserve/recovery con-
tai ner after three or four warm-up/cool down cycl es
to mai ntai n cool ant l evel between the FULL HOT
and ADD marks; i f any trapped ai r was removed
from the system.
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL
(1) Rai se vehi cl e on a hoi st. Remove ri ght i nner
spl ash shi el d.
(2) Remove accessory dri ve bel ts. Refer to proce-
dure i n thi s secti on.
(3) Drai n cool i ng system. Refer to Cool i ng System
Drai ni ng i n thi s secti on.
(4) Remove power steeri ng pump attachi ng bol ts
and set pump and assembl y asi de. Power steeri ng
l i nes do not need to be di sconnected.
(5) Remove upper and l ower torque i sol ator struts.
(6) Support engi ne from the bottom and remove
ri ght engi ne mount attachi ng bol t.
(7) Remove ri ght engi ne mount bracket.
(8) Remove ti mi ng bel t and ti mi ng bel t tensi oner.
Refer to Group 9, Engi ne for procedures.
(9) Remove camshaft sprocket and rear ti mi ng bel t
cover. Refer to Group 9, Engi ne for procedures.
(10) Remove water pump attachi ng screws to
engi ne and remove pump (Fi g. 19).
INSTALLATION
(1) Appl y Mopar௡ Di el ectri c Grease to O-ri ng
before i nstal l ati on.
(2) I nstal l new O-ri ng gasket i n water pump body
O-ri ng groove (Fi g. 20).
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring, resulting in a coolant leak.
(3) Assembl e pump body to bl ock and ti ghten
screws to 12 N·m (105 i n. l bs.). Pressuri ze cool i ng
system to 15 psi wi th pressure tester and check
water pump shaft seal and O-ri ng for l eaks.
Fig. 18 Cooling System Drain Cock Location
1 – DRAIN COCK
Fig. 19 Water Pump
1 – CYLINDER BLOCK
2 – PUMP BODY
PL COOLING SYSTEM 7 - 19
SERVICE PROCEDURES (Continued)
(4) Rotate pump by hand to check for freedom of
movement.
(5) I nstal l rear ti mi ng bel t cover and camshaft
sprocket.
(6) I nstal l ti mi ng bel t tensi oner and ti mi ng bel t.
Refer to Group 9, Engi ne for procedure.
(7) I nstal l ri ght engi ne mount bracket. Refer to
Group 9, Engi ne for procedure.
(8) I nstal l upper and l ower torque i sol ator struts.
Refer to Group 9, Engi ne for procedure.
(9) Fi l l cool i ng system. Refer to procedures i n thi s
secti on.
(10) I nstal l accessory dri ve bel ts. Refer to proce-
dure i n thi s secti on.
(11) Perform camshaft and crankshaft ti mi ng
rel earn procedure as fol l ows:
• Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
• Turn the i gni ti on swi tch on and access the “mi s-
cel l aneous” screen.
• Sel ect “re-l earn cam/crank” opti on and fol l ow
di recti ons on DRB screen.
WATER PUMP INLET TUBE
The i nl et tube connects the water pump to the
radi ator and heater core. Thi s tube i s seal ed by an
O-ri ng and hel d i n pl ace by fasteners to the bl ock.
REMOVAL
CAUTION: Do not use any sharp tools to remove
hoses from inlet tube. This may cause the tube to
leak.
(1) Drai n cool i ng system. Refer to procedure i n
thi s secti on.
(2) Remove upper radi ator hose to access the hose
connecti ons at the i nl et tube.
(3) Remove i ntake mani fol d. Refer to Group 9,
Engi ne for procedure.
(4) Remove l ower radi ator hose and heater hose
from the i nl et tube.
(5) Remove l ower i ntake mani fol d support bracket.
(6) Remove the i nl et tube to the bl ock fasteners.
(7) Rotate tube whi l e removi ng the tube from the
engi ne bl ock (Fi g. 21).
INSTALLATION
(1) I nspect the O-ri ng for damage before i nstal l i ng
the tube i nto the cyl i nder bl ock (Fi g. 21). Repl ace
O-ri ng as necessary.
(2) Lubri cate O-ri ng wi th Mopar௡ Di el ectri c
Grease and i nstal l i nl et tube i nto the cyl i nder bl ock
openi ng.
(3) I nstal l i nl et tube fasteners and ti ghten fasten-
ers to 12 N·m (105 i n. l bs.).
(4) I nstal l i ntake mani fol d l ower support bracket
fasteners and ti ghten to 12 N·m (105 i n. l bs.).
(5) Connect l ower radi ator hose and heater hose to
i nl et tube.
(6) I nstal l i ntake mani fol d. Refer to Group 9,
Engi ne for procedure.
(7) I nstal l upper radi ator hose.
(8) Fi l l cool i ng system. Refer to procedure i n thi s
secti on.
(9) Pressure system to 104 kPa (15 psi ) to check
for l eaks.
ENGINE THERMOSTAT
REMOVAL
(1) Drai n cool i ng system to the thermostat l evel or
bel ow.
(2) Remove cool ant recovery/reserve system hose
and upper radi ator hose.
Fig. 20 Water Pump Body
1 – IMPELLER
2 – PUMP BODY
3 – O-RING
Fig. 21 Water Pump Inlet Tube
1 – O-RING
2 – WATER PUMP INLET TUBE
FRONT
7 - 20 COOLING SYSTEM PL
REMOVAL AND INSTALLATION (Continued)
(3) Remove thermostat/engi ne outl et connector
bol ts (Fi g. 22).
(4) Remove thermostat and O-ri ng assembl y.
INSTALLATION
(1) Cl ean al l seal i ng surfaces.
(2) Pl ace the new thermostat assembl y i nto the
thermostat housi ng/outl et connector. Al i gn vent wi th
notch i n cyl i nder head.
(3) I nstal l thermostat housi ng/outl et connector
onto cyl i nder head and ti ghten bol ts to 12.5 N·m (110
i n. l bs.).
(4) I nstal l upper radi ator hose.
(5) Connect the cool ant recovery/reserve system
hose.
(6) Refi l l cool i ng system. Refer to procedure i n thi s
secti on.
RADIATOR
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n cool i ng system. Refer to procedure i n
thi s secti on.
(3) Remove upper radi ator hose from the radi ator.
(4) Di sconnect and cap automati c transmi ssi on
hoses, i f equi pped.
(5) Di sconnect cool i ng fan motor el ectri cal connec-
tor.
(6) Remove cool i ng fan modul e retai ni ng screws,
l ocated on the top of the shroud (Fi g. 23). Li ft shroud
up and out of bottom shroud attachment cl i ps sepa-
rati ng shroud from radi ator.
(7) Remove the l ower radi ator hose.
(8) Remove upper radi ator i sol ator bracket mount-
i ng screws (Fi g. 24). Di sconnect the engi ne bl ock
heater wi re, i f equi pped.
(9) Remove the ai r condi ti oni ng condenser attach-
i ng screws l ocated at the front of the radi ator, i f
equi pped (Fi g. 25), then l ean condenser forward.
NOTE: It is not necessary to discharge the air con-
ditioning system to remove the radiator.
Fig. 22 Thermostat/Engine Outlet Connector
1 – PRESSURE CAP
2 – THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR
3 – THERMOSTAT
4 – O-RING
5 – VENT FACING UP
Fig. 23 Fan Module Mounting
1 – SCREWS
2 – LOWER MOUNTS
3 – FAN MOTOR ELECTRICAL CONNECTOR
Fig. 24 Radiator Mounting
1 – UPPER RADIATOR HOSE
2 – UPPER RADIATOR MOUNTS
PL COOLING SYSTEM 7 - 21
REMOVAL AND INSTALLATION (Continued)
(10) Radi ator can now be l i fted free from engi ne
compartment. Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1) Sl i de radi ator down i nto posi ti on behi nd radi a-
tor support (yoke).
(2) Attach ai r condi ti oni ng condenser to radi ator, i f
equi pped (Fi g. 25), wi th four mounti ng screws.
Ti ghten screws to 5.4 N·m (50 i n. l bs.). Then seat the
radi ator assembl y l ower rubber i sol ators i nto the
mounti ng hol es provi ded i n the l ower crossmember.
(3) I nstal l and ti ghten radi ator i sol ator mounti ng
bracket screws to 10 N·m (90 i n. l bs.) (Fi g. 24). The
radi ator shoul d have cl earance to move up, approxi -
matel y 5–8 mm (0.20–0.31 i n.) after assembl ed.
(4) I nstal l l ower radi ator hose. Al i gn the hose and
posi ti on the cl amp so i t wi l l not i nterfere wi th engi ne
components.
(5) Connect automati c transmi ssi on hoses, i f
equi pped. Ti ghten hose cl amps to 2 N·m (18 i n. l bs.).
(6) Sl i de fan modul e down i nto cl i p(s) on l ower
radi ator fl ange (Fi g. 23). I nstal l retai ni ng screws and
ti ghten to 7.5 N·m (65 i n. l bs.).
(7) Connect the cool i ng fan motor el ectri cal connec-
tor.
(8) I nstal l upper radi ator hose. Al i gn the hose and
posi ti on the cl amp so they wi l l not i nterfere wi th the
engi ne or the hood.
(9) Connect negati ve cabl e to battery.
(10) Fi l l cool i ng system wi th cool ant. Refer to pro-
cedure i n thi s secti on.
(11) Operate engi ne unti l i t reaches normal operat-
i ng temperature. Check cool i ng system and auto-
mati c transmi ssi on for correct fl ui d l evel s.
RADIATOR DRAINCOCK
REMOVAL
(1) Turn the drai n cock stem countercl ockwi se to
unscrew the stem. When the stem i s unscrewed to
the end of the threads, pul l the stem (Fi g. 26) from
the radi ator tank.
INSTALLATION
(1) Push the drai ncock assembl y body i nto the
tank openi ng.
(2) Ti ghten the drai ncock stem by turni ng cl ock-
wi se to 2.0-2.7 N·m (18-25 i n. l bs.).
COOLING FAN MODULE
Al l model s use a si ngl e speed el ectri c motor dri ven
cool i ng system fan. The fan modul e i ncl udes a motor,
fan bl ade, and support shroud. The modul e i s fas-
tened to the radi ator by screws.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(1) Di sconnect negati ve cabl e from battery.
(2) Drai n cool i ng system bel ow upper radi ator hose
l evel . Refer to procedure i n thi s secti on.
(3) Remove upper radi ator hose from radi ator (Fi g.
27).
(4) Di sconnect fan modul e el ectri cal connector.
(5) Remove fan modul e screws from radi ator (Fi g.
28).
(6) Li ft fan shroud up and out of l ower shroud
attachment cl i ps.
(7) Refer to Di sassembl y and Assembl y i n thi s sec-
ti on for fan modul e sub-component servi ce proce-
dures.
Fig. 25 A/C Condenser to Radiator Mounting Screws
1 – AIR CONDITIONING CONDENSER TO RADIATOR
MOUNTING SCREWS
2 – LOWER ISOLATOR MOUNTS
Fig. 26 Draincock
1 – DRAIN COCK BODY
2 – DRAIN COCK HOUSING
7 - 22 COOLING SYSTEM PL
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l the fan modul e i nto the cl i ps on the
l ower radi ator tank.
(2) I nstal l the fan modul e retai ni ng screws and
ti ghten to 7.5 N·m (65 i n. l bs.).
(3) Connect fan modul e el ectri cal connector. For
wiring diagrams of fan motor systems, refer to
Group 8W, Wiring Diagrams.
(4) I nstal l the upper radi ator hose to radi ator (Fi g.
27). Al i gn hose and posi ti on cl amp so i t wi l l not
i nterfere wi th the engi ne or the hood.
(5) Connect negati ve cabl e to battery.
(6) Fi l l cool i ng system. Refer to procedure i n thi s
secti on.
COOLANT RECOVERY CONTAINER
REMOVAL
(1) Di sconnect recovery hose from water outl et
connector/thermostat housi ng (Fi g. 29).
(2) Remove contai ner attachi ng fasteners (Fi g. 30).
(3) Remove cool ant recovery contai ner.
INSTALLATION
(1) I nstal l cool ant recovery contai ner and ti ghten
fasteners to 4 N·m (35 i n. l bs.) (Fi g. 30).
Fig. 27 Upper Radiator Hose
1 – UPPER RADIATOR HOSE
2 – UPPER RADIATOR MOUNTS
Fig. 28 Fan Module—Removal/Installation
1 – SCREWS
2 – LOWER MOUNTS
3 – FAN MOTOR ELECTRICAL CONNECTOR
Fig. 29 Recovery Container Hose
1 – RECOVERY HOSE
2 – ENGINE COOLANT RECOVERY CONTAINER
3 – PRESSURE CAP
Fig. 30 Coolant Recovery Container
1 – COOLANT RECOVERY CONTAINER
2 – SCREW
3 – NUT
PL COOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)
(2) Connect recovery hose to water outl et connec-
tor/thermostat housi ng (Fi g. 29).
(3) Fi l l contai ner to proper l evel . Refer to Cool i ng
System Refi l l i ng i n thi s secti on.
ENGINE BLOCK HEATER
REMOVAL
(1) Drai n cool ant from radi ator and cyl i nder bl ock.
Refer to Cool i ng System Drai ni ng i n thi s secti on for
procedure.
(2) Detach power cord pl ug from heater (Fi g. 31).
(3) Loosen screw i n center of heater. Remove
heater assembl y (Fi g. 31).
INSTALLATION
(1) Thoroughl y cl ean core hol e and heater seat.
(2) I nsert heater assembl y wi th el ement l oop posi -
ti oned upward (Fig. 31).
(3) Wi th heater seated, ti ghten center screw
securel y to assure a posi ti ve seal .
(4) Connect power cord to bl ock heater (Fi g. 31).
(5) Fi l l cool i ng system wi th cool ant to the proper
l evel , vent ai r, and i nspect for l eaks.
ACCESSORY DRIVE BELTS
POWER STEERING PUMP AND AIR CONDITIONING
COMPRESSOR BELT
REMOVAL
(1) Usi ng a 17 mm wrench, rotate bel t tensi oner
cl ockwi se (Fi g. 33) unti l bel t can be removed from
power steeri ng pump pul l ey. Gentl y, rel ease spri ng
tensi on on tensi oner.
(2) Remove bel t (Fi g. 34).
INSTALLATION
(1) I nstal l bel t (Fi g. 34) over al l pul l eys except for
the power steeri ng pump pul l ey.
(2) Usi ng a 17 mm wrench, rotate bel t tensi oner
cl ockwi se (Fi g. 33) unti l bel t can be i nstal l ed onto
power steeri ng pul l ey. Rel ease spri ng tensi on onto
bel t.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
(3) After bel t i s i nstal l ed, i nspect bel t l ength i ndi -
cator marks (Fi g. 35). The i ndi cator mark shoul d be
wi thi n the mi ni mum bel t l ength and maxi mum bel t
l ength marks. On a new bel t, the i ndi cator mark
shoul d al i gn approxi matel y wi th the nomi nal bel t
l ength mark.
Fig. 31 Engine Block Heater
1 – CORE PLUG
2 – BLOCK HEATER
3 – POWER CORD
Fig. 32 Accessory Drive Belts
1 – GENERATOR BELT
2 – AUTOMATIC BELT TENSIONER
3 – POWER STEERING PUMP/A/C COMPRESSOR BELT
7 - 24 COOLING SYSTEM PL
REMOVAL AND INSTALLATION (Continued)
GENERATOR BELT
REMOVAL
(1) Remove power steeri ng pump/ai r condi ti oni ng
compressor dri ve bel t.
(2) Loosen pi vot bol t, then l ocki ng nut and adjust-
i ng bol t (Fi g. 36).
(3) Remove generator bel t.
NOTE: When installing drive belt onto pulleys,
make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
INSTALLATION
(1) I nstal l bel t and/or adjust bel t tensi on by ti ght-
eni ng adjusti ng bol t. Adjust bel t to speci fi cati on
shown i n Bel t Tensi on Chart.
NOTE: Due to space limitations, the use of a belt
tension gauge is limited. Therefore, measure the
belt deflection at the center span of the generator
belt. Refer to Belt Tension Chart for specifications.
(2) Ti ghten pi vot bol t to 54 N·m (40 ft. l bs.) and
l ocki ng nut to 54 N·m (40 ft. l bs.) (Fi g. 36).
Fig. 33 Accessory Belt—Removing
1 – 17mm WRENCH
Fig. 34 Power Steering/Air Conditioning Belt
1 – BELT
2 – P/S PULLEY
3 – TENSIONER PULLEY
4 – CRANKSHAFT PULLEY
5 – BELT
6 – P/S PULLEY
7 – TENSIONER PULLEY
8 – A/C PULLEY
9 – CRANKSHAFT PULLEY
PL COOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l power steeri ng pump and A/C compres-
sor dri ve bel t.
AUTOMATIC BELT TENSIONER & PULLEY
The automati c bel t tensi oner (Fi g. 37) mai ntai ns
proper tensi on on the power steeri ng and ai r condi -
ti oni ng bel t. The tensi oner i s servi ced wi th the
engi ne mount bracket assembl y. The tensi oner pul l ey
can be servi ced.
NOTE: Slight axial movement of the tensioner arm
is normal. Tensioner arm should move freely and
maintain 50–70 lb. tension on belt.
REMOVAL
(1) Remove engi ne mount bracket assembl y. Refer
to Group 9, Engi ne for procedure.
(2) Remove tensi oner pul l ey mounti ng bol t.
(3) Remove pul l ey.
INSTALLATION
(1) I nstal l tensi oner pul l ey and bol t. Ti ghten bol t
to 27 N·m (20 ft. l bs.).
(2) I nstal l engi ne mount bracket assembl y. Refer
to Group 9, Engi ne for procedure.
DISASSEMBLY AND ASSEMBLY
COOLING FAN MODULE
The cool i ng fan modul e consi st of the fol l owi ng
three components: fan, fan motor, and shroud.
Fig. 35 Belt Length Indicator Marks
1 – AUTOMATIC BELT TENSIONER
2 – BELT LENGTH INDICATOR
3 – MAXIMUM BELT LENGTH
4 – NOMINAL BELT LENGTH
5 – MINIMUM BELT LENGTH
Fig. 36 Generator Belt Adjustment
1 – ADJUSTING BOLT
2 – LOCKING NUT
3 – PIVOT BOLT
BELT TENSION CHART
Accessory
Drive Belt
Belt Tension Belt Deflection
at Center Span*
Power Steering
Pump and A/C
Compressor
Dynamic Tensioner
Generator
New 135 lb. 4.5 mm (0.18 in.)
Used 100 lb. 5.5 mm (0.22 in.)
* Belt deflection is measured at the center of the belt
span with 4.5 kg (10 lb.) force.
7 - 26 COOLING SYSTEM PL
REMOVAL AND INSTALLATION (Continued)
FAN
There are no repai rs to be made to the fan. I f the
fan i s warped, cracked, or otherwi se damaged, i t
must be repl ace wi th only the recommended part for
adequate strength, performance and safety.
REMOVAL
(1) Remove cool i ng fan modul e. Refer to procedure
i n thi s secti on.
(2) Remove fan hub retai ni ng nut (Fi g. 38).
(3) Remove fan from motor shaft.
INSTALLATION
(1) I nstal l fan on motor shaft.
(2) I nstal l fan retai ni ng nut and ti ghten to 3.8
N·m (34 i n. l bs.) (Fi g. 38).
(3) I nstal l cool i ng fan modul e. Refer to procedure
i n thi s secti on.
FAN MOTOR
REMOVAL
(1) Remove cool i ng fan modul e. Refer to procedure
i n thi s secti on.
(2) Remove fan from motor shaft.
(3) Remove screw attachi ng the i n-rush current
suppressor (Fi g. 39).
(4) Remove screws attachi ng motor to shroud (Fi g.
39).
(5) Remove fan motor.
INSTALLATION
(1) I nstal l fan motor on shroud and ti ghten screws
to 3.8 N·m (34 i n. l bs.) (Fi g. 39).
(2) I nstal l screw attachi ng the i n-rush current sup-
pressor and ti ghten to 2.6 N·m (23 i n. l bs.) (Fi g. 39).
(3) I nstal l fan on motor shaft.
(4) I nstal l cool i ng fan modul e. Refer to procedure
i n thi s secti on.
Fig. 37 Automatic Belt Tensioner
1 – GENERATOR BELT
2 – AUTOMATIC BELT TENSIONER
3 – POWER STEERING PUMP/A/C COMPRESSOR BELT
Fig. 38 Fan—Removal and Installation
1 – FAN
2 – NUT
3 – SHROUD ASSEMBLY
Fig. 39 Fan Motor—Removal and Installation
1 – FAN MOTOR SCREWS
2 – IN RUSH CURRENT SUPPRESSOR SCREW
PL COOLING SYSTEM 7 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
SHROUD
REMOVAL
(1) Remove cool i ng fan modul e. Refer to procedure
i n thi s secti on.
(2) Remove fan and fan motor as previ ousl y
descri bed.
INSTALLATION
(1) I nstal l fan motor and fan as previ ousl y
descri bed.
(2) I nstal l cool i ng fan modul e. Refer to procedure
i n thi s secti on.
CLEANING AND INSPECTION
WATER PUMP
Repl ace water pump body assembl y i f i t has any of
these defects:
(1) Cracks or damage on the body.
(2) Cool ant l eaks from the shaft seal , evi dent by
cool ant traces on the pump body.
(3) Loose or rough turni ng beari ng.
(4) I mpel l er rubs ei ther the pump body or the
engi ne bl ock.
(5) I mpel l er l oose or damaged.
(6) Sprocket or sprocket fl ange l oose or damaged.
ACCESSORY DRIVE BELT INSPECTION
Bel t repl acement under any or al l of the fol l owi ng
condi ti ons i s requi red, excessi ve wear, frayed cords or
severe gl azi ng.
Pol y-V Bel t system may devel op mi nor cracks
across the ri bbed si de. These mi nor cracks are con-
si dered normal and acceptabl e. Cracks paral l el are
not (Fi g. 40).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
COOLING SYSTEM CAP
Hol d the cap i n your hand, right side up (Fi g. 41).
The vent val ve at the bottom of the cap shoul d open
wi th a sl i ght pul l . I f the rubber gasket has swol l en,
preventi ng the val ve from openi ng, repl ace the cap.
I f any l i ght can be seen between vent val ve and
the rubber gasket, repl ace the cap. Use only a
replacement cap that has a spring to hold the
vent shut.
A repl acement cap must be of the type desi gned for
cool ant reserve systems. Thi s desi gn ensures system
pressuri zati on.
COOLING SYSTEM CLEANING
(1) Drai n cool i ng system. Refer to Cool i ng System
Drai ni ng i n thi s secti on for procedure.
(2) Refi l l wi th cl ean water. Refer to Cool i ng Sys-
tem Refi l l i ng i n thi s secti on for procedure.
(3) Run engi ne wi th radi ator cap i nstal l ed unti l
upper radi ator hose i s hot.
(4) Stop engi ne and drai n water from system. I f
water i s di rty, fi l l , run and drai n the system agai n
unti l water runs cl ear.
RADIATOR FLUSHING
(1) Drai n cool i ng system. Refer to Cool i ng System
Drai ni ng i n thi s secti on for procedure.
(2) Remove radi ator hoses from engi ne.
(3) I nstal l sui tabl e fl ushi ng gun i n radi ator l ower
hose.
(4) Fi l l radi ator wi th cl ean water and turn on ai r
i n short bl asts.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedure until water runs
clear.
ENGINE FLUSHING
(1) Drai n radi ator. Refer to Cool i ng System Drai n-
i ng i n thi s secti on for procedure.
(2) Remove hoses from radi ator.
Fig. 40 Drive Belt Wear Pattern
1 – NORMAL CRACKS BELT OK
2 – NOT NORMAL CRACKS REPLACE BELT
7 - 28 COOLING SYSTEM PL
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove engi ne thermostat and rei nstal l ther-
mostat housi ng. A gasket may be needed to seal the
housi ng to cyl i nder head because the seal i s part of
thermostat.
(4) I nstal l sui tabl e fl ushi ng gun to thermostat
housi ng hose. Turn on water, and when engi ne i s
fi l l ed, turn on ai r, but no hi gher than 138 kPa (20
psi ) i n short bl asts. Al l ow engi ne to fi l l between
bl asts of ai r. Conti nue thi s procedure unti l water
runs cl ean.
(5) I nstal l thermostat and fi l l cool i ng system.
Refer to Cool i ng System Refi l l i ng i n thi s secti on for
procedure.
REVERSE FLUSHING
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system, usi ng ai r
pressure i n a di recti on opposi te to that of the normal
fl ow of water. Thi s i s onl y necessary wi th di rty sys-
tems and evi dence of parti al pl uggi ng.
CHEMICAL CLEANING
One type of corrosi on encountered wi th al umi num
cyl i nder heads i s al umi num hydroxi de deposi ts. Cor-
rosi on products are carri ed to the radi ator and depos-
i ted when cool ed off. They appear as dark grey when
wet and whi te when dry. Thi s corrosi on can be
removed wi th a two part cl eaner (oxal i c aci d and
neutral i zer) avai l abl e i n auto parts outl ets. Fol l ow
manufacturers di recti ons for use.
ADJ USTMENTS
BELT TENSION
For bel t tensi on adjustment procedure, refer to
Accessory Dri ve Bel t Removal and I nstal l ati on proce-
dure.
Fig. 41 Cooling System Pressure Cap
1 – PRESSURE RATING
2 – FILLER NECK SEAL
3 – PRESSURE VALVE
4 – VACUUM VENT VALVE (SHOWN IN SEALING POSITION)
PL COOLING SYSTEM 7 - 29
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE SPECIFICATIONS
SPECIAL TOOLS
COOLING
6.2 Liters (6.5 qts.)
CAPACITY, Includes Heater and Coolant Reserve
System
DESCRIPTION N·m Ft.
Lbs.
In.
Lbs.
A/C Condenser to Radiator—
Screws
5.4 — 50
Automatic Belt Tensioner
Pulley—Bolt
27 20 —
Coolant Recovery Container—
Nut/Screw
4 — 35
Fan Module to Radiator—
Screws
7.2 — 65
Fan Motor to Shroud—Screws 3.8 — 34
Fan Blade to Motor Shaft—
Nut
3.8 — 34
In Rush Current Supressor—
Screw
2.6 — 23
Generator Mounting—Pivot
Bolt
54 40 —
Generator Mounting—Locking
Nut
54 40 —
Radiator (Cooling Module) to
Body—Screws
10 — 90
Thermostat Housing/Water
Outlet Connector—Screws
12 — 105
Transmission Hose—Clamps 2 — 18
Water Pump to Engine
Block—Bolts
12 — 105
Water Pump Inlet Tube to
Engine Block—Bolts
12 — 105
Hose Clamp Pliers 6094
Coolant Refractometer 8286
7 - 30 COOLING SYSTEM PL