.

COOLING SYSTEM

7 - 1

COOLING SYSTEM
CONTENTS
page

page

ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 23

ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 26
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 28

GENERAL INFORMATION
COOLING SYSTEM
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
The cooling system has a radiator, coolant, electric
fan motor, shroud, pressure cap, thermostat, coolant
reserve system, transmission oil cooler, a water pump
to circulate the coolant, hoses, and clamps to complete the circuit.

When Engine is cold: Thermostat is closed, cooling

system has no flow through the radiator. The coolant
bypass flows through the engine only.
When Engine is warm: Thermostat is open, cooling
system has bypass flow and coolant flow through radiator.
Its primary purpose is to maintain engine temperature in a range that will provide satisfactory engine
performance and emission levels under all expected
driving conditions. It also provides hot water (coolant) for heater performance and cooling for automatic
transmission oil. It does this by transferring heat

Fig. 1 Cooling System Operation 2.5L Engine

7 - 2

COOLING SYSTEM

Fig. 2 Cooling System Operation3.0 Engine

from engine metal to coolant, moving this heated
coolant to the radiator, and then transferring this
heat to the ambient air.
Coolant flow circuits for 2.5L engine equipped vehicles is shown in Figure 1. Figure 2 shows 3.0L engine
coolant routing. Figure 4 shows 3.3/3.8L Engine Coolant routing.
Excluding heated intake manifold hose routing
(hose is routed from waterbox directly to heater), all
other system functions are essentially the same as
shown for standard engines.

3.0L WATER PIPES

The 3.0L engine uses metal piping beyond the
lower radiator hose to route (suction) coolant to the
water pump, which is in the V of the cylinder banks.
(Fig. 3)
These pipes are provided with inlet nipples for
thermostat bypass and heater return coolant hoses,
and brackets for rigid engine attachment. The pipes
employ O-rings for sealing at their interconnection
and to the water pump (Fig. 3).

Fig. 3 Engine Inlet Coolant Pipes3.0L Engine

COOLING SYSTEM

Fig. 4 Cooling System Operation3.3/3.8L Engines

7 - 3

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COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS

COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS

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COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS

COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS

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COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS

COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS

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7 - 10

COOLING SYSTEM
SERVICE PROCEDURES

WATER PUMPS
A quick test to tell whether the pump is working is
to see if the heater warms properly. A defective pump
can not circulate heated coolant through the long
heater hose.
The water pump on all models can be replaced without discharging the air conditioning
system.

WATER PUMP 2.5L ENGINE

The water pump has a diecast aluminum body and
housing with a stamped steel impeller. The pump
uses an O-ring gasket between body and housing.
The assembly bolts directly to the block. Cylinder
block to water pump sealing uses a rubber O-ring.

(5) Remove water pump attaching screws to engine

(Fig. 1).
DISASSEMBLY
(1) Remove three screws holding pulley to water
pump.
(2) Remove nine screws holding water pump body
to housing. Remove the pump body from housing.
(Fig. 2)
(3) Clean gasket surfaces on water pump housing
and engine block.
(4) Remove and discard O-ring gaskets and clean
O-ring grooves.

Fig. 2 Water Pump Components2.5L Engines

Fig. 1 Water Pump2.5L Engine

REMOVAL
(1) Drain cooling system. Refer to Draining Cooling
System in this group.
(2) If equipped with air conditioning, see Solid
Mount Accessory Bracket in (Standard Service Procedures) Group 9, Engine:
(a) Remove air conditioning compressor and generator from solid mount bracket and set aside. It is
not necessary to discharge the a/c system.
(b) Remove solid mount bracket.
(3) If the vehicle is not equipped with air conditioning, remove generator and mounting bracket.
(4) Disconnect lower radiator and heater hoses
from pump.

INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Water leaks from the shaft seal, evident by
coolant traces below the vent hole.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
housing.
ASSEMBLY
Body assembly and housing are serviced as separate components.
(1) Install new O-ring gasket in body O-ring
groove.
(2) Assemble pump body to housing and tighten
nine screws to 12 Nzm (105 in. lbs.) (Fig. 2).
(3) Rotate pump by hand to check for freedom of
movement.
(4) Position water pump pulley to water pump. Install three screws and tighten to 30 Nzm (250 in.
lbs.).
(5) Position new O-ring in housing to block O-ring
groove.

COOLING SYSTEM

7 - 11

INSTALLATION
(1) Install water pump on engine. Tighten top
three screws (Fig. 1) to 30 Nzm (250 in. lbs.). Install
lower screw and tighten to 68 Nzm (50 ft. lbs.).
(2) Install bypass/heater hose and lower radiator
hose.
(3) Install generator and air conditioning compressor bracket(s). For solid mount bracket see standard
service procedures in Group 9 Engine.
(4) Install generator and air conditioning compressor.
(5) Refill cooling system. See Refilling Cooling
System.
(6) Install drive belt, See Accessory Drive Belts,
this Group.

WATER PUMP 3.0L ENGINE

The pump bolts directly to the engine block, using
a gasket for pump to block sealing (Fig. 3). The pump
is serviced as a unit.
The water pump is driven by the timing belt. See
Timing System in Group 9, Engine for component removal providing access to water pump.

Fig. 4 Water Pump Inspection

Fig. 5 Water Pipe O-Ring

INSTALLATION
(1) Clean all gasket and O-ring surfaces on pump
and water pipe inlet tube.
(2) Install new O-ring on water inlet pipe (Fig. 5).
Wet the O-ring (with water) to ease assembly.

Fig. 3 Water Pump3.0L Engine

REMOVAL
(1) Drain cooling system. Refer to Draining Cooling
System in this group.
(2) Remove mounting bolts.
(3) Separate pump from water inlet pipe (Figs. 3
and 4) and remove.
INSPECTION
Replace the water pump if it has any of the following defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks, if the shaft seal is leaking, evident by traces of coolant leaks from vent hole A in
(Fig. 4).
(3) Impeller rubs the inside of pump.
(4) Loose or rough turning bearing.

CAUTION: Keep the O-ring free of oil or grease.

(3) Install new gasket on water pump and install
pump inlet opening over water pipe, press assembly
to cause water pipe insertion into pump housing.
(4) Install pump to block mounting bolts and
tighten to 27 Nzm (20 ft. lbs.).
(5) See Timing System in Engine, Group 9 and install timing belt. Reassemble engine.
(6) Fill cooling system. See Refilling Cooling System.

WATER PUMP 3.3/3.8L ENGINES

The pump has a die cast aluminum body and a
stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring for sealing. It is driven by
the back surface of the Poly-V Drive Belt.

7 - 12

COOLING SYSTEM

INSTALLATION
(1) Install new O-ring in O-ring groove (Fig. 7).
(2) Install pump to chain case cover. Torque screws
to 12 Nzm (105 in. lbs.)
(3) Rotate pump by hand to check for freedom of
movement.
(4) Position pulley on pump. Install screws and
torque to 30 Nzm (250 in. lbs.).
(5) Install drive belt. See Accessory Drive Belts
this group.
(6) Install right front lower fender shield.
(7) Refill Cooling System. See Refilling Cooling
System.

ENGINE THERMOSTAT
Fig. 6 Water Pump3.3/3.8L Engines
REMOVAL
(1) Drain Cooling System. Refer to Draining Cooling System in this group.
(2) Remove Poly V Drive Belt.
(3) Remove right front lower fender shield.
(4) Remove pump pulley bolts and remove pulley.
(5) Remove pump mounting screws (Fig. 6). Remove pump.
(6) Remove and discard O-ring seal.
(7) Clean O-ring groove and O-ring surfaces on
pump and chain case cover. Take care not to scratch
or gouge sealing surface.
INSPECTION
Replace the water pump if it has any of the following defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; if the seal is leaking, evident by
traces of coolant leaks from vent hole.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or chain
case cover.

Fig. 7 Water Pump Body

The 2.5L engine thermostat is located on the front

of the engine (radiator side) in the waterbox that is
part of the cylinder head construction (Fig. 8).
These thermostats do not have an air bleed notch.
The 3.0L and 3.3/3.8L engine thermostats are in
water boxes, formed in the timing belt end of the intake manifold. These thermostat have air bleed
valves, located in the thermostat flange (Figs. 9 and
10).

DESCRIPTION AND OPERATION

The engine cooling thermostats are wax pellet
driven, reverse poppet choke type. They are designed
to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88 to 93C
(192 to 199F). They also automatically reach wide
open so they do not restrict flow to the radiator as
temperature of the coolant rises in hot weather to
around 104C (220F). Above this temperature the
coolant temperature is controlled by the radiator, fan,
and ambient temperature, not the thermostat.
OPERATION AND TESTING
The thermostat operates by a wax filled container
(pellet) that is sealed so that when heated to a predetermined temperature. The wax expands enough to
overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage
into the pellet will cause a thermostat to fail open.
Do not attempt to free up a thermostat with a screwdriver.
The open too soon type failure mode is included in
the on-board diagnosis. The check engine light will
not be lit by an open too soon condition. Only if the
thermostat has failed open, a code 17 will be set. Do
not change a thermostat for lack of heat by gauge or
heater performance, unless code 17 is present, see diagnosis for other probable causes. Failing shut is the
normal long term mode of failure, and normally, only
on high mileage vehicles. The temperature gauge will
show this, Refer to diagnosis in this section.

.
REMOVAL
(1) Drain cooling system down below the thermostat level . Refer to Draining Cooling System in this
group.
(2) Remove thermostat housing bolts and housing
(Figs. 8, 9 and 10).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.

COOLING SYSTEM

7 - 13

ing. Bolt housing to water box (Fig. 8 ). Tighten bolts

to 28 Nzm (250 in. lbs.). Refill cooling system (see Refilling System).

INSTALLATION3.0L ENGINE
Center thermostat in water box pocket. Check that
the flange is seated correctly in the countersunk portion of the intake manifold water box (Figs. 9 and
10). Install new gasket on water box. Install housing
over gasket and thermostat and tighten bolts to 12
Nzm (133 in. lbs.).

Fig. 8 Thermostat, Housing, and Water Box2.5L

Engine
Fig. 10 Thermostat Installed3.0L Engine

Fig. 9 Thermostat, Housing, and Water Box3.0L

Engine
INSTALLATION2.5L ENGINE
Place a new gasket (dipped in clean water) on water box surface, center thermostat in water box on
gasket. Place housing over gasket and thermostat,
making sure thermostat is in the thermostat hous-

Fig. 11 Thermostat, Housing and Waterbox3.3/3.8L

Engines
INSTALLATION3.3/3.8L ENGINES
Place a new gasket (dipped in water) on the water
box surface, center thermostat into opening in the intake manifold. Place housing over gasket and ther-

7 - 14

COOLING SYSTEM

mostat, making sure thermostat is in recess provided

(Fig. 11). Bolt housing to intake manifold, tighten
bolts to 28 Nzm (250 in. lbs.). Refill cooling system
(see Refilling System).

COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves. Then
carry this heat to the radiator where the tube/fin assemblies of these components can give it up to the
air.

PERFORMANCE
Performance is measurable. For heat transfer pure
water excels (Formula = 1 btu per minute for each
degree of temperature rise for each pound of water).
This formula is altered when necessary additives to
control boiling, freezing, and corrosion are added as
follows:
Pure Water (1 btu) boils at 100C (212F) and
freezes at 0C (32F)
100 percent Glycol (.7 btu) can cause a hot engine
and detonation and will lower the freeze point to
-22C (-8F).
50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of
-37C(-35F). The radiator, water pump, engine water
jacket, radiator pressure cap, thermostat, temperature gauge, sending unit and heater are all designed
for 50/50 glycol.
Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of-59C
(-50F).
CAUTION: Richer mixtures cannot be measured
with field equipment that can lead to problems associated with 100 percent glycol.

SELECTION AND ADDITIVES

The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion
protection. Mopar Antifreeze, Prestone II, Peak or
antifreeze containing Alugard 340-2, or their equivalent is recommended for best engine cooling without
corrosion. When mixed only to a freeze point of-37C
(-35F) to -59C (-50F). If it loses color or becomes
contaminated, drain, flush, and replace with fresh
properly mixed solution.
SERVICE
Coolant should be changed at 52,500 miles or three
years, whichever occurs first, then every two years or
30,000 miles.

ROUTINE LEVEL CHECK

Do not remove radiator cap for routine coolant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without removing the radiator cap. Simply observe, with the
engine idling and warmed up to normal operating
temperature, that the level of the coolant in the reserve tank (Fig. 15) is between the minimum and
maximum marks.

ADDING ADDITIONAL COOLANT

The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant reserve tank.
Use only 50/50 mix of ethylene glycol type antifreeze
and water.

SERVICE COOLANT LEVEL

The cooling system is closed and designed to maintain coolant level to the top of the radiator.
When servicing requires a coolant level check in
the radiator, the engine must be off and not under
pressure. Drain several ounces of coolant from the
radiator drain cock while observing the Coolant Recovery System (CRS) Tank. Coolant level in the CRS
tank should drop slightly. Then remove the radiator
cap. The radiator should be full to the top. If not, and
the coolant level in the CRS tank is at the MIN mark
there is an air leak in the CRS system. Check hose
or hose connections to the CRS tank, radiator filler
neck or the pressure cap seal to the radiator filler
neck for leaks.
LOW COOLANT LEVEL AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running operating temperature the high pressure
inlet tank runs full and the low pressure outlet tank
drops. If this level drops below the top of the transmission oil cooler, air will be sucked into the water
pump:
Transmission oil will become hotter.
High reading shown on the temperature gauge.
Air in the coolant can cause loss of flow through
the heater.
Exhaust gas leaks into the coolant also can cause
the same problems?
DEAERATION
Air can only be removed from the system by gathering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the CRS
tank by thermal expansion of the coolant. It then escapes to the atmosphere in the CRS tank and is replaced with solid coolant on cool down.

COOLING SYSTEM

7 - 15

COOLING SYSTEM DRAIN, CLEAN FLUSH AND

REFILL
Drain, flush, and fill the cooling system at the
mileage or time intervals specified in the Maintenance Schedule in this Group. If the solution is dirty
or rusty or contains a considerable amount of sediment, clean and flush with a reliable cooling system
cleaner. Care should be taken in disposing of the
used engine coolant from your vehicle. Check governmental regulations for disposal of used engine coolant.

DRAINING COOLING SYSTEM

To drain cooling system move temperature selector
for heater to full heat with engine running (to provide vacuum for actuation). Without removing radiator pressure cap and with system not under
pressure, Shut engine off and open draincock. The
coolant reserve tank (Fig. 15) should empty first,
then remove radiator pressure cap. (if not, see Testing Cooling System for leaks). To vent 2.5L engine remove the plug above thermostat housing (Fig. 12). To
vent 3.3/3.8L engines remove the engine temperature
sending unit (Fig. 13).

Fig. 13 Engine Temperature Sending Unit3.3/3.8L

Engines Drain/Fill
REVERSE FLUSHING
Reverse flushing of the cooling system, is the forcing of water through the cooling system, using air
pressure in a direction opposite to that of the normal
flow of water. This is usually only necessary with
very dirty systems with some evidence of partial
plugging.
RADIATOR
Drain cooling system and remove radiator hoses
from engine. Install suitable flushing gun in radiator
lower hose. Fill radiator with clean water and turn
on air in short blasts.
CAUTION: Internal radiator pressure must not exceed 138 kPa (20 psi) as damage to radiator may result. Continue this procedure until water runs clear.

Fig. 12 Thermostat Housing Drain/Fill Plug2.5L

Engine
Removal of a plug or other component is required
because these thermostats do not have an air vent
and prevents air flow through it. This allows the
coolant to drain from the engine block.

CLEANING
Drain cooling system (see: Draining Cooling System) and refill with clean water (see Refilling Cooling System). Run engine with radiator cap installed
until upper radiator hose is hot. Stop engine and
drain water from system. If water is dirty, fill, run
and drain system again until water runs clear.

ENGINE
Drain radiator (see: Draining Cooling System)
and remove hoses from radiator. Remove engine thermostat and reinstall thermostat housing. Install suitable flushing gun to thermostat housing hose. Turn
on water, and when engine is filled, turn on air, but
no higher than 138 kPa (20 psi) in short blasts. Allow
engine to fill between blasts of air. Continue this procedure until water runs clean. Reinstall thermostat
using a new housing gasket. Fill cooling system (See
Refilling).

CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Corrosion products are carried to the radiator and deposited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be removed with a two part cleaner (oxalic acid and neutralizer) available in auto parts outlets. Follow
manufacturers directions for use.

7 - 16

COOLING SYSTEM

REFILLING
First clean system to remove old glycol, see Cooling
System Cleaning.
Fill system, using antifreeze described in Coolant.
Fill 50
of capacity with 100
glycol. Then complete filling system with water.
The 2.5L engine requires venting by removal of the
plug on top of the water box (Fig. 12). The 3.3/3.8L
engines require the removal of the Engine Temperature Sending Unit on the front of the cylinder head
(Fig. 13). When coolant reaches this hole;
Install vent plug and tighten to 20 Nzm (15 ft. lbs.)
for 2.5L Engines.
Install Engine Temperature Sending Unit and
tighten to 7 Nzm (60 in. lbs.) for 3.3/3.8L Engines.
Continue filling system until full, this provides better heater performance. Be careful not to spill
coolant on drive belts or the generator.
Fill coolant reserve system to at least the MAX
mark with 50/50 solution. It may be necessary to add
coolant to the reserve tank after three or four warm
up, cool down cycles to maintain coolant level between the MAX and MIN mark. This will allow
trapped air to be removed from the system.

Fig. 14 Pressure Testing Cooling System

appear intermixed with the oil it will indicate an internal leak in the engine. If there is an internal leak,
the engine must be disassembled for repair.

TESTING SYSTEM FOR LEAKS

With engine not running, wipe the radiator filler
neck sealing seat clean. The radiator should be full.
Attach the Tester Radiator Pressure Tool to the radiator, as shown in (Fig. 14) and apply 104 kPa (15
psi) pressure. If the pressure drops more than 2 psi
in 2 minutes inspect all points for external leaks.
All hoses, radiator and heater, should be shaken
while at 104 kPa (15 psi) since some leaks occur only
while driving due to engine rock, etc.
If there are no external leaks, after the gauge dial
shows a drop in pressure, detach the tester. Start engine and run the engine up to normal operating temperature to open the thermostat and allow the
coolant to expand. Reattach the tester. If the needle
on the dial fluctuates it indicates a combustion leak,
usually a head gasket leak.

COOLANT RECOVERY SYSTEM (CRS)

This system works with the radiator pressure cap
to use thermal expansion and contraction of the coolant to keep the coolant free of trapped air. Provides a
convenient and safe method for checking coolant
level and adjusting level at atmospheric pressure
without removing the radiator pressure cap. It also
provides some reserve coolant to cover minor leaks
and evaporation or boiling losses. All vehicles are
equipped with this system and take various shapes
and forms. (Fig. 15) shows a typical system in the
typical location.

WARNING: WITH TOOL IN PLACE, PRESSURE WILL

BUILDS UP FAST. EXCESSIVE PRESSURE BUILT
UP, BY CONTINUOUS ENGINE OPERATION, MUST
BE RELEASED TO A SAFE PRESSURE POINT.
NEVER PERMIT PRESSURE TO EXCEED 138 KPA
(20 PSI).
If the needle on the dial does not fluctuate, race
the engine a few times. If an abnormal amount of
coolant or steam emits from the tail pipe, it may indicate a coolant leak caused by a faulty head gasket,
cracked engine block, or cracked cylinder head.
There may be internal leaks that can be determined by removing the oil dip-stick. If water globules

Fig. 15 Typical Coolant Recovery System

COOLING SYSTEM

See Coolant Level Check Service and Deaeration,

and Pressure Cap sections for operation and service.
Vehicles equipped with the electric monitor system
have a level sensor in the CRS tank, see Group 8,
Electrical, for service.

RADIATOR PRESSURE CAP

Radiators are equipped with a pressure cap that
releases pressure at some point within a range of 97124 kPa (14-18 psi).
The system will operate at higher than atmospheric pressure that raises the coolant boiling point
allowing increased radiator cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting allowing coolant to return to radiator
from coolant reserve system tank by vacuum through
connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean
the vent valve (Fig. 16) to ensure proper sealing
when boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.

Fig. 16 Radiator Pressure Cap Filler Neck

RADIATOR CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at
the radiator filler neck nipple (Fig. 16). Attach the
Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at 55 kPa (8 psi) minimum.

(1)
(2)
(3)
(4)

Check and adjust antifreeze freeze point.

Refill system with new anti-freeze.
Conducting service procedures.
Checking for vacuum leaks.

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,

WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTER-CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP 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 RADIATOR CAP

Dip the pressure cap in water, clean any deposits
off the vent valve or its seat and apply cap to end of
Radiator Pressure Tool. Working the plunger, bring
the pressure to 104 kPa (15 psi) on the gauge. If the
pressure cap fails to hold pressure of at least 97 kPa
(14 psi) replace cap. See CAUTION.
If the pressure cap tests properly while positioned
on Radiator Pressure Tool (Fig. 17), but will not hold
pressure or vacuum when positioned on the radiator.
Inspect the radiator filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
CAUTION: Radiator Pressure Tool is very sensitive
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 tool upside down and
recheck pressure cap to confirm that cap is bad.

WARNING: THE WARNING WORDS DO NOT OPEN

HOT ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
time except for the following purposes:

7 - 17

Fig. 17 Pressure Testing Radiator Cap

7 - 18

COOLING SYSTEM

INSPECTION
Hold the cap in hand, right side up (Fig. 16). The
vent valve at the bottom of the cap should open. If
the rubber gasket has swollen and prevents the valve
from opening, replace the cap.
Hold the cleaned cap in hand upside down. If any
light shows between vent valve and rubber gasket,
replace cap. Do not use a replacement cap that
has a spring to hold the vent shut.
Replacement cap must be of the type designed for
coolant reserve system with a completely sealed dia-

phragm spring, and rubber gasket to seal to filler

neck top surface. This design assures coolant return
to radiator.

RADIATOR
The radiators are cross-flow types (horizontal
tubes) with design features that provide greater
strength also sufficient heat transfer capabilities to
keep the engine satisfactorily cooled (Figs. 1 and 2).

Fig. 1 Cooling ModuleStandard Duty

Fig. 2 Cooling ModuleHeavy Duty Trailer Tow

COOLING SYSTEM

CAUTION: Plastic tanks, while stronger then brass

are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.

7 - 19

RADIATOR
REMOVAL
(1) Disconnect negative battery cable from battery.

If the plastic tank is damage, replace the radiator.

RADIATOR DRAINCOCK SERVICE

Fig. 3 Draincock Assembled

REMOVAL
CAUTION: Use of pliers on draincock is not recommended. Damage may occur to part. Draincock
should not be removed unless leakage observed.
(1) Turn the draincock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
the end of the threads turn back 1/8 turn and, pull
the stem (Fig. 3) from the radiator tank.

WARNING: DO NOT REMOVE THE CYLINDER

BLOCK OR THE RADIATOR DRAINCOCK WITH THE
SYSTEM HOT AND UNDER PRESSURE BECAUSE
SERIOUS BURNS FROM COOLANT CAN OCCUR.
(2) Drain cooling system. Refer to Draining Cooling
System of this section.
(3) Remove hose clamps and hoses from the radiator (Fig. 5).
Remove coolant reserve system tank to filler neck
tube.
(4) Remove automatic transmission hoses and auxiliary oil cooler, if equipped.
(5) Remove fan and fan support assembly by disconnecting fan motor electrical connector. Remove
upper shroud fasteners, and lift shroud up and out of
bottom shroud attachment clips separating shroud
from radiator. Fan damage should always be avoided.
(6) Remove front grille. Refer to Group 23 Body for
procedure.
(7) Remove A/C condenser fasteners and separate
the condenser from the radiator (Fig. 4).
(8) Remove upper radiator mounting screws (Fig.
5). Disconnect the engine block heater wire if
equipped.
(9) Radiator can now be lifted free from engine
compartment. Care should be taken not to damage radiator cooling fins or water tubes during
removal.

INSTALLATION
(1) Push the draincock assembly body into the
tank opening until it snaps into place.
(2) Tighten the draincock stem by turning clockwise until it stops.

RADIATOR COOLANT FLOW CHECK

To determine whether coolant is flowing through
the cooling system, use the following procedure:
(1) If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If it is hot, coolant is circulating.
WARNING: DO NOT REMOVE RADIATOR PRESSURE CAP WITH THE SYSTEM HOT AND UNDER
PRESSURE BECAUSE SERIOUS BURNS FROM
COOLANT CAN OCCUR.
(2) Remove radiator pressure cap when engine is
cold, Idle engine until thermostat opens, you should
observe coolant flow while looking down the filler
neck. Once flow is detected install radiator pressure
cap.

Fig. 4 Air Conditioning Condenser Mounting Screws

7 - 20

COOLING SYSTEM

Fig. 5 Engine Cooling Module MountingAll Models

INSTALLATION
(1) Slide radiator down into position behind radiator support (yoke). Seat the radiator with the rubber
isolators into the mount holes provided, with a 10
lbs. force .
(2) Install the upper radiator mounting screws.
Tighten radiator mounting bolts to 12 Nzm (105 in.
lbs.) (Fig. 5).
(3) Install Air Conditioning Condenser onto the radiator (Fig. 4).
(4) Install front grille. Refer to Group 23 Body for
procedure.
(5) Connect automatic transmission hoses (if
equipped).
(6) Slide fan shroud, fan and motor down into clips
on lower radiator tank. Attach upper shroud screws.
(7) Install upper, lower radiator hoses (including
coolant reserve hose) (Fig. 5) and fan motor electrical
connection. See Refilling Cooling Systems.
(6) Connect negative battery cable.

RADIATOR HOSES AND CLAMPS

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP
TOWEL OVER THE CAP AND WITHOUT PUSHING
DOWN ROTATE IT COUNTER-CLOCKWISE TO THE

FIRST STOP. ALLOW FLUIDS TO ESCAPE

THROUGH THE OVERFLOW TUBE AND WHEN THE
SYSTEM STOPS PUSHING OUT COOLANT AND
STEAM AND PRESSURE DROPS.
The hoses are removed by using constant tension
clamp pliers to compress hose clamp.
A hardened, cracked, swollen or restricted hose
should be replaced. Do not damage radiator inlet and
outlet when loosening hoses.
Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended.
Spring type hose clamps are used in all applications. If replacement is necessary replace with the
original MOPAR equipment spring type clamp.

FANS
All models use electric motor driven cooling system
fan. The fan modules include a motor, shroud and
fan. The module is fastened to the radiator by screws
(Fig. 6).
All fan motors are two speed. Attempts to reduce
high temperature gauge reading by increasing engine
speed, at the same vehicle speed, can increase high
temperature.

COOLING SYSTEM

FAN MODULE SERVICE

There are no repairs to be made to the fan or support assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as a assembly.

7 - 21

The fan will not run during cranking until the engine starts no matter what the coolant temperature
is.

TEMPERATURE GAUGE INDICATION

At idle with Air Conditioning off the temperature
gauge will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to
about 1/2 gauge travel this is normal.

ELECTRIC FAN MOTOR

ELECTRIC FAN MOTOR TEST
Refer to Powertrain Diagnostic Manual for procedure
SERVICE
CAUTION: DO NOT DISASSEMBLE THE FAN MOTOR FROM THE SUPPORT BRACKET.

Fig. 6 Fan Module

REMOVAL
(1) Disconnect the fan motor electrical connector.
(2) Remove upper shroud fasteners, and lift shroud
up and out of bottom shroud attachment clips separating shroud from radiator (Fig. 6). Fan damage
should always be avoided.
INSTALLATION
(1) Install fan module assembly into attaching clips
on the bottom of the radiator (Fig. 6). Attach support
screws tighten screws to 12 Nzm (105 in. lbs.).
(2) Connect fan motor lead. For wiring diagrams
of fan motor systems refer to 8W Wiring Diagrams.
RADIATOR FAN CONTROL
Fan control is accomplished two ways. A pressure
transducer on the compressor discharge line sends a
signal to the powertrain control module (PCM) which
will activate the fan. In addition to this control, the
fan is turned on by the temperature of the coolant
which is sensed by the coolant temperature sensor
which sends the message to the Engine Controller.
The Engine Controller turns on the fan through the
fan relay. See Wiring Diagrams Manual for circuity
and diagnostics provided.
Switching through the Powertrain Control Module
(PCM) provides fan control for the following conditions;
Air Conditioning NOT Activated
All Engines:
Low Speed Fan ON 104 C (220 F)
Low Speed Fan OFF 98.993 C (210 F)
High Speed Fan ON 110 C (230 F)
High Speed Fan OFF 104 C (219 F)

Electric fan motor is serviced as an assembly with

the fan module.
For wiring diagrams of fan motor systems refer to 8W Wirig Diagrams.

AUTOMATIC TRANSMISSION OIL COOLERS

STANDARD DUTY
This style oil cooler is an internal oil to coolant
type mounted in the radiator side tank (Fig. 7). This
style cooler uses rubber oil lines to feed oil to and
from the cooler. Use only approved transmission oil
cooler hose. Since these are molded to fit space available, molded hoses are recommended.

Fig. 7 Transmission Oil CoolerStandard Duty

7 - 22

COOLING SYSTEM

HEAVY DUTY TRAILER TOW

Is a external oil-to-air type mounted ahead of the
radiator (Fig. 8). This style cooler uses rubber oil
lines to feed oil from the internal cooler to the external and then to the automatic transmission. Use only
approved transmission oil cooler hose. Since these
are molded to fit space available, molded hoses are
recommended.

Fig. 8 Transmission Oil CoolerHeavy Duty Trailer

Tow

COOLING SYSTEM

7 - 23

ACCESSORY DRIVE BELTS

INDEX
page

page

2.5L Engine Belts Remove/Install-Adjust . . . . . . . . 24

3.0L Engine Belts Remove/Install-Adjust . . . . . . . . 25
3.3/3.8L Engines Accessory Drive Belt Remove/
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

General Information

GENERAL INFORMATION

For conventional V-belts affix the Burroughs gauge

(Special Tool C-4162) to the belt. Adjust the belt tension for New or Used belt as prescribed in the Belt
Tension Chart. For a Poly-V belt affix the Poly-V
Burroughs gauge to the belt and then apply specified
tension to the belt as prescribed in the Belt Tension
Chart
Adjust the belt tension for a New or Used belt as
prescribed in the Belt Tension Chart.

PROPER BELT TENSION

Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning
should be performed with the aid of a Burroughs
gauge Special Tool C-4162. Because of space limitations in the engine compartment of front wheel drive
vehicles, the gauge may be restricted to use after the
vehicle has been raised on a hoist and the splash
shield has been removed.
Belt tensioning methods are given in order of preference:
Belt tension gauge method.
Torque equivalent method.
BELT TENSION GAUGE METHOD
Use belt tensioning Special Tool Kit C-4162 for:

. . . . . . . . . . . . . . . . . . . . . . . 23

TORQUE EQUIVALENT METHOD

Adjustable accessory brackets provided with a
13mm (1/2 in.) square hole for a torque wrench can
use an equivalent torque value for belt adjustment.
Equivalent torque values for adjusting these accessory drive belts are specified on the Belt Tension
Chart.

CAUTION: The Burroughs gauge for the Poly-V belt

is not to be used on the V-belt. These gauges are
not interchangeable.

ACCESSORY DRIVE BELTS DIAGNOSIS

7 - 24

COOLING SYSTEM

Fig. 1 Drive Belt Inspection

2.5L ENGINE BELTS REMOVE/INSTALL-ADJUST

AIR CONDITIONING COMPRESSOR
(1) Loosen the idler bracket pivot screw A and locking screws B (Fig. 2) to remove and install belt or adjust belt tension. The lower locking screw B must be
removed to install accessory drive belt.
(2) Adjust belt tension by applying torque to
square hole C on idler bracket. Adjust tension to
specification given in Belt Tension Chart.
(3) Tighten in order, first, locking screws B then
pivot screw A to 54 Nzm (40 ft. lbs.).

POWER STEERING PUMPS TYPE

(1) From on top of the vehicle loosen locking screw
G.
(2) From under the vehicle loosen the pivot screw
and pivot nut H.
(3) After installing a new belt adjust belt tension
with 1/2 in. breaker bar installed in adjusting
bracket. See tension specification in Belt Tension
Chart.
(4) Tighten locking screw G to 54 Nzm (40 ft. lbs.).
(5) Tighten pivot screw H and the pivot nut to 54
Nzm (40 ft. lbs.)
GENERATOR BELT
(1) Loosen generator pivot nut D.
(2) Loosen T-Bolt locking nut E and adjusting
screw F to remove and install Poly V belt or adjust
belt tension.
(3) Tighten pivot nut D TO 54 Nzm (40 ft. lbs.).
(4) Tighten adjusting screw F to adjust belt tension
to specification shown in Belt Tension Chart.
(5) Tighten T-Bolt locking nut E to 54 Nzm (40 ft.
lbs.)

Fig. 2 Accessory Drive Belts2.5L Engine

COOLING SYSTEM

3.0L ENGINE BELTS REMOVE/INSTALL-ADJUST

AIR CONDITIONING BELT
To remove and install the air conditioning compressor drive belt, first loosen the idler pulley lock nut,
then turn the adjusting screw to raise or lower the
idler pulley (Figs. 3 and 4).

7 - 25

3.3/3.8L ENGINES ACCESSORY DRIVE BELT

REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR
CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT
The Poly-V Drive belt is provided with a dynamic
tensioner (Fig. 6) to maintain proper belt tension. To
remove or install this belt.
(1) Raise vehicle on hoist.
(2) Remove right front splash shield.
(3) Release tension by rotating the tensioner clockwise (Fig. 6).
(4) Reverse above procedure to install.

Fig. 3 Accessory Drive Belts3.0L Engine

To adjust the air conditioning drive belt,
loosen the idler pulley nut (Fig. 3) and adjust belt
tension by tightening adjusting screw (Figs. 3 and 4).
Tighten pulley nut to 54 Nzm (40 ft. lbs.) after adjustment.

GENERATOR/POWER STEERING PUMP BELT

The Poly-V generator/power steering pump belt is
provided with a dynamic tensioner (Fig. 5) to maintain proper belt tension. To remove or install this
belt, apply force in a clockwise direction to the tensioner pulley bolt (Fig. 5).

Fig. 5 Release Belt Tensioner

Fig. 4 Air Conditioning Belt Idler

Fig. 6 Accessory Drive Belt3.3/3.8L Engines

7 - 26

COOLING SYSTEM
BELT TENSION CHART

ENGINE BLOCK HEATER

DESCRIPTION AND OPERATION
On all models an engine block heater is available
as an optional accessory. The heater is operated by
ordinary house current (110 Volt A.C.) through a
power cord located behind the radiator grille. This
provides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures. The heater is mounted in a core
hole (in place of a core hole plug) in the engine block,
with the heating element immersed in coolant (Fig.
7).
The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become
damaged.
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.

REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and Refill of this section for procedure.
(2) Detach power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop positioned upward.
(3) With heater seated, tighten center screw securely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize system with Radiator Pressure Tool before looking for
leaks.

COOLING SYSTEM

Fig. 7 Block Heater Assembly2.5L, 3.0L and 3.3/3.8L Engines

.
7 - 27

7 - 28

COOLING SYSTEM
SPECIFICATIONS
TORQUE

COOLING SYSTEM CAPACITY