Chapter 3 Cooling, heating and ai r conditioning systems Contents Air conditioning compressor — removal and installation 4 Air conditioning system — servicing 13 Amtitreeze — general information 2 Coolant level check ‘See Chapter 1 Cooling system check See Chapter 1 Cooling system servicing See Chapter 1 Fan — removal and installation 6 Fan thermocouple — removal and installation 7 1 General information| Heater circulation pump — removal and installation 2 Heater control valve — removal and installation 4 Heater fan motor — removal and installation 10 Radiator — removal, servicing and installation 5 Thermostat — check 4 Thermostat — replacement a Water pump — check 8 Water pump — removal and installation a Specifications Cooling system capacity (approximate) Coolant type Radiator cap opening pressure Thermostat ‘Starts to open Fully open Torque specifications Fan-to-water pump hub Fan thermocouple-to-fan bolt ‘Thermostat housing bolt Water pump-to-block bolt 1. General information| ‘The cooling system consists of a radiator, an engine-driven water pump end fan with thermostat controlled coolant flow. A fluid-type thermocouple allows the fan to free-wheel until air passing through the radiator is hot enough to activate it. Later models are equipped with @ coolant recovery system which ‘consists ofa plastic reservoir connected to the radiator by a tube. The reservoir retains coolant forced out of the radiator and through the tube by expansion. When the engine cools and the coolant contracts, itis drawn back into the radiator, 12 US ats (11 liters) 55/45 mix of ethylene glycol antifreeze and water 103 kPa (15 psi) 178° to 193°F (80° to 90°C} 193° to 200°F (90 to 94°C) Nm Felbs 25 18 25 18 10 7 33, 24 ‘The heater utilizes the heat produced by the engine, which is ab sorbed by the coolant to warm the vehicle interior. The coolant, under pressure from the water pump and the auxiliary electrical heater circu lation pump, passes through a heater core similar to 8 small radiator in the passenger compartment. Air directed through the core by the blower motor and duct system heats the vehicle interior. Coolant flow ‘through the heater is controlled by the driver or passenger by way of the heater control valve. ‘Air conditioning is available as an option on these vehicles. The air ‘conditioning system is located in the engine compartment and the com. pressor is turned by the crankshaft pulley-driven drivebelt.108 Chapter 3. Cooling, heating and air conditior Fig. 3.1 Typical 1 Thermostat housing cover 2 Rubber O-ring 3 Thermostat pump component layout (Sec 3, 4 and 9) 4. Thermostat housing 5 Gasket 6 Water pump ig systems 2. Antifreeze — general information Waring: Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle. Flush contacted areas immediately ‘with plenty of water. Wipe up garage floor and drip pan coolant spills immediately. Keep antifreeze containers covered and repair leaks in your cooling system quickly ‘The cooling system should be filled with a water/ethylene glyco! based antifreeze solution, which will prevent freezing down to at least “20°F at all times. It also provides protection against corrosion and increases the coolant boiling point. “The cooling system should be drained, flushed and refilled as per the scheduled intervals (see Chapter 1). The use of antifreeze solutions for periods longer than specified is likely to cause damage and en- courage the formation of rust and scale in the system. Before adding antifreeze to the system, check all hose connections. [Antifreeze tends to search out and leak through very minute openings. ‘The exact mixture of antifreeze-to-water which you should use {depends on the relative weather conditions. The mixture should contain ‘at least 55 percent antifreeze, but should never contain more than 70, percent antifreeze. 3. Thermostat — replacement Caution: The engine must be completely coo! before beginning this procedure. 1 Refer to the Warning in Section 2. terminal of the battery, as this would once again allow power into the electrical system of the vehicle. 3 Drain the cooling system until the level is below the thermostat by loosening the radiator or coolant reservoir cap and removing the plug the bottom of the radiator. Install the plug when enough coolant has drained 4. Onlater models, disconnect the lower radiator hose from the ther ‘mostat housing. 5 Remove the retaining bolts and separate the cover from the thermo- stat housing. 6 Grasp the housing cover securely, rock it back and forth to break the gasket seal and remove it from the engine. Fig. 3.2 Typical later model thermostat housing and water pump component layout (Sec 3, 4 and 9) 1 Thermostat housing cover 4 Thermostat housing 2 Rubber thermostat gasket 5 Gasket 3 Thermostat 6 Water pumpChapter 3 Cooling, heating and air conditioning systems 109 7 Remove the thermostat from the engine block cavity iphoto). 8 Before installing the thermostat, clean the gasket sealing surfaces fon the water outlet and thermostat housing. These surfaces must be perfectly smooth to prevent leakage. 8 On models so equipped, install the rubber gasket secu new thermostat (photo), YO Place the thermostat in the housing 11, On models 50 equipped, instal the O-ring securely in the thermostat housing cover (photol. 12 Install the housing cover and bolts. Tighten the bolts to the specified torque. 13 Connect the lower radiator hose and tighten the hose clamp securely 14 Fill the cooling system with the proper antireeze/water mixture (refer to Chapter 1) fon the _ 4 Thermostat — check — 1 The best way to check the operation of the thermostat is with it femoved from the engine. In most cases, if the thermostat is suspect, itis more economical to simply buy and installa replacement thermo Stat, as they are not very costly. However, the checking procedure is 0 follows. 2. Remove the thermostat as described in Section 3, 3. Inspect the thermostat for excessive corrosion and damage, 3.7. Pull the thermostat from the cavity 3.10 Insert the thermostat into the housing Replace it with a new one if either of these conditions is noted. 4 Place the thermostat in hot water (25 degrees above the ‘temperature stamped on the thermostat). The water temperature should be approximately 200 degrees. When submerged in the water (which should be agitated thoroughly), the valve should open all the way. 8 Next, remove the thermostat using a piace of bent wire and place itin water which is 10 degrees below the temperature on the thermo: stat, or about 165 degrees. At this temperature, the thermostat valve should close completely. 6 Reinstall the thermostat if it operates properly. If it does not, pur chase a new thermostat of the same temperature rating 5 Radiator — removal, servicing and instal — — ——— Note: The engine must be completely coo! before beginning this procedure. 1. Refer to the Warning in Section 2. 2. Disconnect the negative cable at the battery. Place the cable out Of the way 30 it eannot accidentally come in contact with the negative terminal of the battery, as this would once again allow power into the ‘electrical system of the vehicle. 3. Drain the radiator (refer to Chapter 1, if necessary. 4 Disconnect the coolant and recovery hoses from the radiator. 5 Remove the two radiator attaching clips and hang the fan shroud ‘out of the way over the fan (photo ik 3.9 Work the gasket securely around the thermostat. Note that the thermostat edge fits into a slit (arrow) in the gasket 5.5 Release the radiator clips with screwdriver5.7. The locations of the oll cooler bracket (lower left arrow) and various automatic transmission cooler hose connections 6.38 The retaining bolts are accessible from the back side of the fan 6 Raise the front of the vehicle and support it securely on jackstands. 7 Disconnect the oil cooler bracket and automatic transmission cooler hose connections at the bottom of the radiator (photo). Plug the hose tends to prevent further draining and contamination while the radiator is out of place. 8 Lift the radiator carefully from the engine compartment (photo). 9 Carefully examine the radiator for evidence of leaks and damage. Itis recommended that any necessary repairs be performed by @ radiator repair shop, 40 With the radiator removed, brush accumulations of insects and leaves from the fins and examine and replace, i necessary, any hoses. ‘oF clamps which have deteriorated 11. The radiator can be flushed as described in Chapter 1 12 If you are installing a new radiator, transfer the fittings from the old unit, 113 Installation is the reverse of removal, making sure the rediator seats securely in the mounts. 14. After installing the radiator, refit with the proper coolant mixture (refer to Chapter 1). Also check the automatic transmission fluid evel to replenish fluid which may have leaked from the hoses. Start the engine and check for leaks around the various hoses. Chapter 3. Cooling, heating and air conditioning systems 5.8. Lift the radiator straight up and out of the compartment, Be careful, the fins are very fragi 6.3b Grind or file the end of a box wrench (arrow) to provide the clearance necessary to remove the fan bolts be left in place. A suitable box wrench which has been ground down ‘on ane side for clearance will make removal easier because the area ‘around the bolts is very restricted (photos). 4 Installation is the reverse of removal 7 Fan thermocouple — removal and installation 1 Disconnect the negative battery cable. 2 Remove the radiator (Section 6) and the fan (Section 6). 3. Remove the retaining bolts and lft the thermocouple off ofthe fan (ot 4 hota. Installation is the reverse of removal. 1. Disconnect the battery negative cable. 2 Remove the radiator (Section 5) 3 Remove the fan retaining bolts accessible on the back side of the hhub, If only the fan is to be removed, the pulley and drivebelts can 8 Water pump — check 1A failure of the water pump can cause overheating and serious engine damage (the pump will nat circulate coolant through the engine). 2. There are three ways to check the operation of the water pump ‘while itis stil installed on the engine. If the pump is defective, it shouldChapter 3 Cooling, heating and air conditioning systems 9.5. The water crossover pipe is held in place by two bolts, (arrows) be replaced with a new or rebuilt unit. 3 With the engine at normal operating temperature, squeeze the up- per radiator hose. If the water pump is working properly, a pressure Surge will be felt as the hose is released. 4 Water pumps are equipped with" weep” or vent holes. If a pump seal falure occurs, small amounts of coolant will leak from the weep holes (photo) 8. If the water pump shaft bearings fail, there may be @ squealing Sound emitted from the front of the engine while it is running. Shaft ‘wear can be felt if the water pump pulley is forced up and down. — 9 Water pump — removal and installation ce Note: The engine must be completely coo! before beginning this procedure. 1. Refer to the Warning in Section 2. 2 Disconnect the negative battery cable. 3. Drain the cooling system (refer to Chapter 1, if necessary} 4 Remove the radiator, fan, upper and Iower pulleys and the engine drivebelts. 18.4 Check for leakage at the water pump ‘weep’ hole (arrow) (fan removed for clarity! 9.6 The water pump retaining bolts (arrows); note that the balancer has be fotated so the notch provides access to the lower bolt 5 Disconnect the radiator and heater hoses and remove the crossover pipe from the water pump housing (photo). 8 Remove the water pump bolts. If necessary, turn the balancer until the notch allows access to the lower bolt (photo) 7" Remove the water pump and housing assembly from the engine, Using a rocking motion if necessary, to disengage it. 8 Carefully clean all gasket material from the mounting surfaces of the water pump and engine. These surfaces must be completely smooth in order to prevent leakage. 9 Coat both sides of the gasket with sealant and place it in position fon the water pump housing 40 Place the housing in position and install the retaining bolts finger tight 11 Tighten the bolts evenly in a criss-cross pattern to the specified torque 12 ‘The remainder of installation is the reverse of removal 13 Refill the cooling system with @ 60/80 mixture of water and anti- freeze (Chapter 1). 14 Connect the battery negative cable, start the engine and run it until hormal operating temperature is reached, then check for leaks.112 Chapter 3. Cooling, heating and air conditioning systems + Ny 10.3 After the cover is removed, unplug the elect which is now visible 11.2. Pry upward using two screwdrivers to unplug the connector 11.4 The heater control valve retaining bolts and heater hose connections (arrows) 10 Heater fan motor — removal and i Disconnect the battery negative cable, Remove the cover panel under the right side of the dash. Unplug the electrical connectors (photo). Remove the retaining screws. Lower the motor from the housing (photo) Installation is the reverse of removal, 11 Heater control valve — removal and installation 1 Disconnect the negative battery cable. 2. Use two screwdrivers to unplug the electrical connector (photo) 2 Clamp the hose off with lacking pliers or a similar tool or place ' suitable size container under the valve to catch the coolant when the hose is disconnected 4 Remove the two hose clamps and two retaining bolts and lift the valve from the engine compartment (photo). 5 Installation is the reverse of removal ymoval and installation 12 He ulation pump — 1 _ The heater circulation pump is located in the engine compartment incline with the heater hose. Begin removal by disconnecting the negative battery cable. 2. Place a container or newspapers under the pump to catch the ‘coolat 3 Unplug the electrical connector, disconnect the hoses and remove the pump (photo), 4° Installation is the reverse of removal 13. Air conditioning system — servicing Warning: The air conditioning system is under high pressure. Do not disassemble any portion of the system thoses, compressor, ine fittings, ‘ete,) without having the system depressurized by a dealer or competent repair facility, 1 Raise the hood 2. The condenser is located just forward of the radiator. Inspect theChapter 3. Cooling, heating and air conditioning systems 12.3 Heater circulation pump electrical connector and hose connections (arrows) 14.5. Air compressor pipe bracket nut and bolt (arrows) condenser fins and brush away any leaves and bugs. Check the electric fan and wiring connectors which are also in this area. Replacement of these components is straightforward once the system has been de pressurized (photo). Fr Check the condition of the system hoses. if there is any sign of deterioration or hardening, have them replaced by a dealer or air condi tioning repair facility 4 At the recommended intervals, check and adjust the compressor drivebelt as described in Chapter 1 8 Because of the special tools, equipment and skills required to ser Vice air conditioning systems, and the differences between the various Systems that may be installed on vehicles, ar conditioning repair other than indicated here cannot be covered in this manual. 113 13.2 The air conditioning condenser is located in front of the radiator and is easily checked with the hood open. 14.6 Air conditioning compressor retaining bolts (arrows) 14. Air conditioning compressor — removal and installation 11 Take the vehicle to a properly equipped shop and have the air condi toning system depressurized 2 Disconnect the battery negative cable. 3. Remove the compressor drivebelt. ‘4 Raise the front of the vehicle and suppor it securely on jackstands. 5 Working from under the engine compartment, disconnect the air Conditioning hoses and the bracket at the compressor (photo). On Vehicles with an automatic transmission, the fluid fines near the com- pressor may have to be disconnected to provide adequate working Clearance, 6. Remove the retaining bolts and lower the compressor from the engine (photo), 7 installation isthe reverse of removal. Adjust the drivebelt tension {as described in Chapter 1. Have the system recharged and check for proper operation,