Arrefecimento

ZJ COOLING SYSTEM 7-1
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 22

COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WATER PUMP TESTS . . . . . . . . . . . . . . . . . . . . . 9
COOLING SYSTEM COMPONENTS . . . . . . . . . . 2 SERVICE PROCEDURES
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2 ADDING ADDITIONAL COOLANT . . . . . . . . . . . 24
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . . 1 COOLANT LEVEL CHECK—SERVICE . . . . . . . . 24
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COOLING SYSTEM CLEANING/REVERSE
SYSTEM COOLANT ROUTING . . . . . . . . . . . . . . 2 FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
WATER PUMP BYPASS HOSE—5.2L V-8 DRAINING AND FILLING COOLING SYSTEM . . 24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ROUTINE COOLANT LEVEL CHECK . . . . . . . . . 24
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELT TENSION . . . . . . . . . . 3 AUTOMATIC BELT TENSIONER . . . . . . . . . . . . 44
AUTOMATIC TRANSMISSION OIL COOLERS . . . 2 BELT REPLACEMENT/ADJUSTMENT . . . . . . . . 43
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . . 5 COOLING SYSTEM FAN 4.0L ENGINE . . . . . . . 45
COOLANT RESERVE/OVERFLOW SYSTEM . . . . 2 COOLING SYSTEM FAN 5.2L ENGINE . . . . . . . 46
COOLANT SELECTION-ADDITIVES . . . . . . . . . . . 5 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 42
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . 6 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 4 THERMOSTAT 4.0L ENGINE . . . . . . . . . . . . . . . 32
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . . 5 THERMOSTAT 5.2L ENGINE . . . . . . . . . . . . . . . 33
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TRANSMISSION OIL COOLER—AUXILIARY . . 26
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 7 VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 46
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 6 WATER PUMP 4.0L ENGINE . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING WATER PUMP 5.2L ENGINE . . . . . . . . . . . . . . 29
BELT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 10 WATER PUMP BYPASS HOSE . . . . . . . . . . . . . 39
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 15 CLEANING AND INSPECTION
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FAN BLADE INSPECTION . . . . . . . . . . . . . . . . . 47
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . . 9 RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . 47
LOW COOLANT LEVEL-AERATION . . . . . . . . . . 24 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 8 WATER PUMP INSPECTION . . . . . . . . . . . . . . . 47
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . 14 SPECIFICATIONS
PRESSURE TESTING RADIATOR CAP . . . . . . . 23 COOLING SYSTEM CAPACITIES . . . . . . . . . . . . 47
RADIATOR CAP-TO-FILLER NECK SEAL— DRIVE BELT TENSION . . . . . . . . . . . . . . . . . . . 48
PRESSURE RELIEF CHECK . . . . . . . . . . . . . . 23 INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
RADIATOR COOLANT FLOW CHECK . . . . . . . . 21 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TESTING COOLING SYSTEM FOR LEAKS . . . . 21 SPECIAL TOOLS
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 10 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
GENERAL INFORMATION ing in wrong direction. Refer to the appropriate

engine Belt Schematic in this Group for the correct
ENGINE ACCESSORY DRIVE BELTS belt routing. Or, refer to the Belt Routing Label
located in the engine compartment.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to water pump rotat-
7-2 COOLING SYSTEM ZJ
GENERAL INFORMATION (Continued)
COOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.
COOLING SYSTEM COMPONENTS

The cooling system consists of:
• A radiator
• Cooling fan
• Thermal viscous fan drive
• Fan shroud
• Radiator pressure cap
• Thermostat
• Coolant reserve/overflow system
• Transmission oil cooler (if equipped with an
automatic transmission)
• Coolant Fig. 1 Engine Cooling System—4.0L Engine—
• Water pump Typical
• Hoses and hose clamps
Plastic tanks, while stronger than brass, are sub-
ject to damage by impact, such as from tools or
SYSTEM COOLANT ROUTING wrenches. Handle radiator with care.
For cooling system routings refer to (Fig. 1) (Fig.
2).
DESCRIPTION AND OPERATION
WATER PUMP BYPASS HOSE—5.2L V-8 ENGINE
A water pump bypass hose (Fig. 3) is used between AUTOMATIC TRANSMISSION OIL COOLERS
the intake manifold and water pump on all 5.2L V-8 There are two types of automatic transmission oil
engines. coolers:
• An oil-to-coolant type. This is supplied as stan-
COOLANT dard equipment on vehicles with an automatic trans-
The cooling system is designed around the coolant. mission. It is mounted in the radiator outlet tank.
Coolant flows through the engine water jackets • An external auxiliary oil-to-air cooler. This is
absorbing heat produced during engine operation. supplied as optional equipment. It is mounted in
The coolant carries heat to the radiator and heater front of the radiator and air conditioning condenser
core. Here it is transferred to ambient air passing and behind the grille.
through the radiator and heater core fins. The cool-
ant also removes heat from the automatic transmis- COOLANT RESERVE/OVERFLOW SYSTEM
sion fluid in vehicles equipped with an automatic This system works along with the radiator pres-
transmission. sure cap. This is done by using thermal expansion
and contraction of the coolant to keep the coolant
RADIATOR free of trapped air. It provides:
All vehicles are equipped with a cross flow type • A volume for coolant expansion and contraction.
radiator with plastic side tanks.
DESCRIPTION AND OPERATION (Continued)
Fig. 2 Engine Cooling System—5.2L Engine—Typical

• Some reserve coolant to the radiator to cover
minor leaks and evaporation or boiling losses.
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Cool-
ant will then be drawn from the coolant tank and
returned to a proper level in the radiator.
The coolant reserve/overflow system has a radiator
mounted pressurized cap, an overflow tube and a
plastic coolant reserve/overflow tank (Fig. 4) mounted
to the right inner fender.
ACCESSORY DRIVE BELT TENSION

Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
4.0L ENGINE
Belt tension is adjusted at the power steering
Fig. 3 Water Pump Bypass Hose—5.2L Engine pump bracket and idler pulley assemly. There are dif-
ferent types of adjustment gauges for checking either
• A convenient and safe method for checking/ad-
a serpentine or a V-type belt. Refer to the instruc-
justing coolant level at atmospheric pressure. This is
tions supplied with the gauge. Use the correct gauge
done without removing the radiator pressure cap.
when checking belt tension. Place gauge in the mid-
Fig. 5 Block Heater—4.0L 6-Cyl. Engine
Fig. 4 Coolant Reserve/Overflow Tank—Typical

dle of the section of belt being tested (between two
pulleys) to check tension. Do not allow the gauge (or
gauge adapter) to contact anything but the belt.
5.2L ENGINE
It is not necessary to adjust belt tension on the
5.2L engine. The engine is equipped with an auto-
matic belt tensioner. The tensioner maintains correct
belt tension at all times. Due to use of this belt ten-
sioner, do not attempt to use a belt tension gauge on
5.2L engines.
ENGINE BLOCK HEATER

An optional engine block heater (Fig. 5) (Fig. 6)is
available with for all models. The heater is equipped
with a power cord. The cord is attached to an engine
compartment component with tie-straps. The heater
warms the engine providing easier engine starting Fig. 6 Block Heater—5.2L V-8 Engine
and faster warm-up in low temperatures. The heater
is mounted in a core hole of the engine cylinder block THERMOSTAT
in place of a freeze plug with the heating element A pellet-type thermostat controls the operating
immersed in engine coolant. Connect power cord to a temperature of the engine by controlling the amount
grounded 110-120 volt AC electrical outlet with a of coolant flow to the radiator. On all engines the
grounded, three wire extension cord. thermostat is closed below 195°F (90°C). Above this
temperature, coolant is allowed to flow to the radia-
WARNING: DO NOT OPERATE ENGINE UNLESS tor. This provides quick engine warm up and overall
BLOCK HEATER CORD HAS BEEN DISCONNECTED temperature control.
FROM POWER SOURCE AND SECURED IN PLACE. An arrow, plus the word UP is stamped on the
THE POWER CORD MUST BE SECURED IN ITS front flange next to the air bleed. The words TO
RETAINING CLIPS AND ROUTED AWAY FROM RAD are stamped on one arm of the thermostat.
EXHAUST MANIFOLDS AND MOVING PARTS. They indicate the proper installed position.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: longer engine warmup time, unreli- ene-glycol. The freeze point of 50/50 propylene-glycol
able warmup performance, increased exhaust and water is -32 deg. C (-26 deg. F). 5 deg. C higher
emissions and crankcase condensation. This conden- than ethylene-glycol’s freeze point. The boiling point
sation can result in sludge formation. (protection against summer boil-over) of propylene-
glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi),
CAUTION: Do not operate an engine without a compared to 128 deg. C (263 deg. F) for ethylene-gly-
thermostat, except for servicing or testing. col. Use of propylene-glycol can result in boil-over or
freeze-up in Chrysler vehicles, which are designed for
The more common type of thermostat failure, usu- ethylene-glycol. Propylene glycol also has poorer heat
ally found on high mileage vehicles, is a thermostat transfer characteristics than ethylene glycol. This
failed in the shut position. The temperature gauge (if can increase cylinder head temperatures under cer-
equipped) will give an indication of this condition. tain conditions.
Depending upon length of time that vehicle is oper-
ated, pressure cap may vent. This will expel steam Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be
and coolant to coolant reserve/overflow tank and to Used in Chrysler Vehicles
surface below vehicle. Refer to the Diagnosis section Propylene-glycol/ethylene-glycol Mixtures can
of this group. cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
COOLANT PERFORMANCE components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
ETHYLENE-GLYCOL MIXTURES conventional methods of determining freeze point will
The required ethylene-glycol (antifreeze) and water not be accurate. Both the refractive index and spe-
mixture depends upon the climate and vehicle oper- cific gravity differ between ethylene glycol and propy-
ating conditions. The recommended mixture of 50/50 lene glycol.
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti- CAUTION: Richer antifreeze mixtures cannot be
freeze concentration must always be a minimum of measured with normal field equipment and can
44 percent, year-round in all climates. If percentage cause problems associated with 100 percent ethyl-
is lower than 44 percent, engine parts may be ene-glycol.
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided COOLANT SELECTION-ADDITIVES
with a 68 percent antifreeze concentration, which The presence of aluminum components in the cool-
prevents freezing down to -67.7 deg. C (-90 deg. F). A ing system requires strict corrosion protection. Main-
higher percentage will freeze at a warmer tempera- tain coolant at specified level with a mixture of
ture. Also, a higher percentage of antifreeze can ethylene-glycol based antifreeze and water. Chrysler
cause the engine to overheat because the specific Corporation recommends Mopar Antifreeze or equiv-
heat of antifreeze is lower than that of water. alent. If coolant becomes contaminated or looses
color, drain and flush cooling system and fill with
100 Percent Ethylene-Glycol—Should Not Be Used in correctly mixed solution.
Chrysler Vehicles A 0.25 percent emulsifiable oil is added to the radi-
Use of 100 percent ethylene-glycol will cause for- ator at the factory to prevent solder corrosion.
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require CAUTION: Do not use coolant additives that are
the presence of water to dissolve. The deposits act as claimed to improve engine cooling.
insulation, causing temperatures to rise to as high as
149 deg. C (300) deg. F). This temperature is hot
enough to melt plastic and soften solder. The RADIATOR PRESSURE CAP
increased temperature can result in engine detona- All radiators are equipped with a pressure cap.
tion. In addition, 100 percent ethylene-glycol freezes This cap releases pressure at some point within a
at 22 deg. C (-8 deg. F ). range of 97-to-124 kPa (14-to-18 psi). The pressure
relief point (in pounds) is engraved on top of the cap
Propylene-glycol Formulations—Should Not Be Used in (Fig. 7).
Chrysler Vehicles The cooling system will operate at pressures
Propylene-glycol formulations do not meet slightly above atmospheric pressure. This results in a
Chrysler coolant specifications. It’s overall effec- higher coolant boiling point allowing increased radi-
tive temperature range is smaller than that of ethyl- ator cooling capacity. The cap (Fig. 7) contains a
spring-loaded pressure relief valve. This valve opens cated by the antifreeze in the coolant mixture. No
when system pressure reaches the release range of additional lubrication is necessary.
97-to-124 kPa (14-to-18 psi).
CAUTION: All 4.0L 6-cylinder engines are equipped
with a reverse (counterclockwise) rotating water
pump and thermal viscous fan drive assembly.
REVERSE is stamped or imprinted on the cover of
the viscous fan drive and inner side of the fan. The
letter R is stamped into the back of the water pump
impeller (Fig. 8). Engines from previous model
years, depending upon application, may have been
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump or vis-
cous fan drive will cause engine over heating.
Fig. 7 Radiator Pressure Cap—Typical

A vent valve in the center of the cap allows a small
coolant flow through the cap when coolant is below
boiling temperature. The valve is completely closed
when boiling point is reached. As the coolant cools, it Fig. 8 Reverse Rotating Water Pump—4.0L
contracts and creates a vacuum in cooling system. 6-Cylinder
This causes the vacuum valve to open and coolant in A quick test to determine if the pump is working is
reserve/overflow tank to be drawn through connect- to check if the heater warms properly. A defective
ing hose into radiator. If the vacuum valve is stuck water pump will not be able to circulate heated cool-
shut, radiator hoses will collapse on cool-down. ant through the long heater hose to the heater core.
A rubber gasket seals the radiator filler neck. This 5.2L ENGINE: One of the heater hoses is con-
is done to maintain vacuum during coolant cool-down nected to the water pump with a metal coolant
and to prevent leakage when system is under pres- return tube (Fig. 9). A rubber o-ring forms a seal at
sure. the water pump end of the tube.
WATER PUMP COOLING SYSTEM HOSES

A centrifugal water pump circulates coolant Rubber hoses route coolant to and from the radia-
through the water jackets, passages, intake manifold, tor, intake manifold and heater core.
radiator core, cooling system hoses and heater core. The lower radiator hose is spring-reinforced to pre-
The pump is driven from the engine crankshaft by a vent collapse from water pump suction at moderate
single serpentine drive belt on all engines. and high engine speeds.
The water pump impeller is pressed onto the rear
of a shaft that rotates in bearings pressed into the
housing. The housing has two small holes to allow
seepage to escape. The water pump seals are lubri-
Fig. 9 Coolant Return Tube—5.2L V-8 Engine Fig. 11 Clamp Number/Letter Location
WARNING: CONSTANT TENSION HOSE CLAMPS Inspect the hoses at regular intervals. Replace
ARE USED ON MOST COOLING SYSTEM HOSES. hoses that are cracked, feel brittle when squeezed, or
WHEN REMOVING OR INSTALLING, USE ONLY swell excessively when the system is pressurized.
TOOLS DESIGNED FOR SERVICING THIS TYPE OF For all vehicles: In areas where specific routing
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER clamps are not provided, be sure that hoses are posi-
6094) (Fig. 10). SNAP-ON CLAMP TOOL (NUMBER tioned with sufficient clearance. Check clearance
HPC-20) MAY BE USED FOR LARGER CLAMPS. from exhaust manifolds and pipe, fan blades, drive
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- belts and sway bars. Improperly positioned hoses can
ING CONSTANT TENSION CLAMPS. be damaged, resulting in coolant loss and engine
overheating.
Ordinary worm gear type hose clamps (when
CAUTION: A number or letter is stamped into the equipped) can be removed with a straight screw-
tongue of constant tension clamps (Fig. 11). If driver or a hex socket. To prevent damage to
replacement is necessary, use only an original hoses or clamps, the hose clamps should be
equipment clamp with matching number or letter. tightened to 4 N·m (34 in. lbs.) torque. Do not
over tighten hose clamps.
When performing a hose inspection, inspect the
radiator lower hose for proper position and condition
of the internal spring.
VISCOUS FAN DRIVE

Also refer to the previous Cooling System Fan sec-
tion.
The thermal viscous fan drive (Fig. 12) (Fig. 13)is a
silicone-fluid-filled coupling used to connect the fan
blades to the water pump shaft. The coupling allows
the fan to be driven in a normal manner. This is
done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
A thermostatic bimetallic spring coil is located on
Fig. 10 Hose Clamp Tool—Typical the front face of the viscous fan drive unit (Fig. 12)
(Fig. 13). This spring coil reacts to the temperature
of the radiator discharge air. It engages the viscous CAUTION: If the viscous fan drive is replaced
fan drive for higher fan speed if the air temperature because of mechanical damage, the cooling fan
from the radiator rises above a certain point. Until blades should also be inspected. Inspect for fatigue
additional engine cooling is necessary, the fan will cracks, loose blades, or loose rivets that could
remain at a reduced rpm regardless of engine speed. have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
NOISE
NOTE: It is normal for fan noise to be louder (roar-

ing) when:
• The underhood temperature is above the engage-

ment point for the viscous drive coupling. This may
occur when ambient (outside air temperature) is very
high.
• Engine loads and temperatures are high such as
when towing a trailer.
Fig. 12 Viscous Fan Drive—4.0L Engine—Typical • Cool silicone fluid within the fan drive unit is
being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
DIAGNOSIS AND TESTING

ON-BOARD DIAGNOSTICS (OBD)
FOR CERTAIN COOLING SYSTEM
COMPONENTS
Fig. 13 Viscous Fan Drive—5.2L Engine—Typical The powertrain control module (PCM) has been
programmed to monitor certain cooling system com-
Only when sufficient heat is present, will the vis-
ponents:
cous fan drive engage. This is when the air flowing
through the radiator core causes a reaction to the NOTE: If the engine has remained cool for too long
bimetallic coil. It then increases fan speed to provide a period, such as with a stuck open thermostat, a
the necessary additional engine cooling. Diagnostic Trouble Code (DTC) number 17 can be
Once the engine has cooled, the radiator discharge observed at the malfunction indicator lamp. This
temperature will drop. The bimetallic coil again lamp is displayed on the instrument panel as the
reacts and the fan speed is reduced to the previous CHECK ENGINE lamp (Fig. 14).
disengaged speed.
If the problem is sensed in a monitored circuit
CAUTION: Engines equipped with serpentine drive often enough to indicate an actual problem, a DTC is
belts have reverse rotating fans and viscous fan stored. The DTC will be stored in the PCM memory
drives. They are marked with the word REVERSE to for eventual display to the service technician. If the
designate their usage. Installation of the wrong fan problem is repaired or ceases to exist, the PCM can-
or viscous fan drive can result in engine overheat- cels the DTC after 51 engine starts.
ing.
DIAGNOSIS AND TESTING (Continued)
Fig. 14 Check Engine Lamp Location

Certain criteria must be met for a DTC to be
entered into PCM memory. The criteria may be a
specific range of engine rpm, engine temperature
and/or input voltage to the PCM. Fig. 15 Data Link Connector Location
A DTC indicates that the PCM has recognized an ERASING TROUBLE CODES
abnormal signal in a circuit or the system. A DTC After the problem has been repaired, use the DRB
may indicate the result of a failure, but never iden- scan tool to erase a DTC. Refer to the appropriate
tify the failed component directly. Powertrain Diagnostic Procedures service manual for
It is possible that a DTC for a monitored circuit operation of the DRB scan tool.
may not be entered into memory even though a mal-
function has occurred. Refer to On- Board Diagnos- DRB SCAN TOOL
tics (OBD) in Group 14, Fuel Systems for additional For operation of the DRB scan tool, refer to the
information. appropriate Powertrain Diagnostic Procedures ser-
vice manual.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored Diagnostic Trouble Code (DTC) can be dis- WATER PUMP TESTS
played by cycling the ignition key On-Off-On-Off-On
within three seconds and observing the malfunction LOOSE IMPELLER
indicator lamp. This lamp is displayed on the instru- DO NOT WASTE reusable coolant. If solution is
ment panel as the CHECK ENGINE lamp (Fig. 14). clean, drain coolant into a clean container for reuse.
They can also be displayed through the use of the
Diagnostic Readout Box (DRB) scan tool. The DRB WARNING: DO NOT REMOVE THE CYLINDER
connects to the data link connector, left of the steer- BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
ing column above the brake pedal (Fig. 15). For oper- DRAINCOCK WITH THE SYSTEM HOT AND UNDER
ation of the DRB, refer to the appropriate Powertrain PRESSURE. SERIOUS BURNS FROM THE COOL-
Diagnostic Procedures service manual. ANT CAN OCCUR.
EXAMPLES:
• If the lamp (Fig. 14) flashes 1 time, pauses and (1) Drain the cooling system. Refer to Draining
flashes 2 more times, a flashing Diagnostic Trouble Code Cooling System in this group.
(DTC) number 12 is indicated. If this code is observed, it (2) Loosen the fan belt. Refer to Belt Service in the
is indicating that the battery has been disconnected Engine Accessory Drive Belt section of this group.
within the last 50 key-on cycles. It could also indicate (3) Disconnect the lower radiator hose from the
that battery voltage has been disconnected to the PCM. water pump.
In either case, other DTC’s may have been erased. (4) Bend a stiff welding rod or similar device as
• If the lamp flashes 1 time, pauses and flashes 7 shown in (Fig. 16). To prevent breakage of rod, min-
more times, a flashing Diagnostic Trouble Code imum thickness should be 3/16 inch (.187 inches).
(DTC) number 17 is indicated. (5) Position the rod in the water pump inlet and
After any stored DTC information has been observed, attempt to hold the impeller while turning the fan
the display will end with a flashing DTC number 55. pulley. If equipped with a thermal viscous fan drive,
This will indicate the end of all stored information. rotate the water pump shaft with a wrench attached
to one of the fan pulley mounting nuts. If the impel-
7 - 10 COOLING SYSTEM ZJ
ler is loose and can be held with the rod while the THERMOSTAT
fan blades are turning, the pump is defective. Do not
use excessive force when rotating pump shaft. If the ON-BOARD DIAGNOSTICS
impeller turns, the pump is OK. All models are equipped with On-Board Diagnos-
tics for certain cooling system components. Refer to
On-Board Diagnostics (OBD) in the Diagnosis section
of this group for additional information. If the pow-
ertrain control module (PCM) detects low engine cool-
ant temperature, it will record a Diagnostic Trouble
Code (DTC) in the PCM memory. The DTC number
for low coolant temperature is 17. Do not change a
thermostat for lack of heat as indicated by the
instrument panel gauge or heater performance
unless a DTC number 17 is present. Refer to the
Diagnosis section of this group for other probable
causes. For other DTC numbers, refer to On-Board
Diagnostics in the General Diagnosis section of
Group 14, Fuel Systems.
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for diagnostic information
and operation of the DRB scan tool.
BELT DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
Fig. 16 Impeller Test—Typical belt from rib to rib (Fig. 17), are considered normal.
These are not a reason to replace the belt. However,
(6) Connect the hose and install the coolant, or cracks running along a rib (not across) are not nor-
proceed with repairs. mal. Any belt with cracks running along a rib must
be replaced (Fig. 17). Also replace the belt if it has
INSPECTING FOR INLET RESTRICTIONS
excessive wear, frayed cords or severe glazing.
Inadequate heater performance may be caused by
Refer to the Serpentine Accessory Drive Belt Diag-
a metal casting restriction in the water pump heater
nosis charts for further belt diagnosis.
hose inlet.
DO NOT WASTE reusable coolant. If solution is
clean, drain the coolant into a clean container for
reuse.
WARNING: DO NOT LOOSEN THE RADIATOR

DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drain sufficient coolant from the radiator to

decrease the level below the water pump heater hose
inlet.
(2) Remove the heater hose.
(3) Inspect the inlet for metal casting flash or
other restrictions.
NOTE: Remove the pump from the engine before

removing restriction to prevent contamination of
the coolant with debris. Refer to Water Pump
Removal in this group.
Fig. 17 Serpentine Belt Wear Patterns

ZJ COOLING SYSTEM 7 - 11
SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS—4.0L 6-CYLINDER ENGINE
SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS—5.2L 8-CYLINDER ENGINE
PRELIMINARY CHECKS (4) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
ENGINE COOLING SYSTEM OVERHEATING formed on vehicle that may effect cooling system.
Establish what driving conditions caused the com- This may be:
plaint. Abnormal loads on the cooling system such as • Engine adjustments (incorrect timing)
the following may be the cause. • Slipping engine accessory drive belt(s)
(1) PROLONGED IDLE, VERY HIGH AMBIENT • Brakes (possibly dragging)
TEMPERATURE, SLIGHT TAIL WIND AT IDLE, • Changed parts (incorrect water pump rotating in
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED, wrong direction)
OR STEEP GRADES: • Reconditioned radiator or cooling system refill-
Driving techniques that avoid overheating are: ing (possibly under-filled or air trapped in system).
• Idle with A/C off when temperature gauge is at • Rubber and foam air seals not properly installed
end of normal range. to radiator or A/C condenser after a repair.
• Increasing engine speed for more air flow is rec- • Upper and lower portions of radiator fan shroud
ommended. not tightly connected. All air must flow through the
(2) TRAILER TOWING: radiator.
Consult Trailer Towing section of owners manual.
Do not exceed limits. NOTE: If investigation reveals none of the previous
(3) AIR CONDITIONING; ADD-ON OR AFTER items as a cause for an engine overheating com-
MARKET: plaint, refer to Cooling System Diagnosis charts.
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is These charts are to be used as a quick-reference
installed. If not, maximum cooling system compo- only. Refer to the group text for information.
nents should be installed for model involved per
manufacturer’s specifications.
COOLING SYSTEM
RADIATOR COOLANT FLOW CHECK WARNING: HOT, PRESSURIZED COOLANT CAN
The following procedure will determine if coolant is CAUSE INJURY BY SCALDING.
flowing through the cooling system.
If engine is cold, idle engine until normal operating Carefully remove the radiator pressure cap from
temperature is reached. Then feel the upper radiator the filler neck and check the coolant level. Push
hose. If hose is hot, the thermostat is open and water down on the cap to disengage it from the stop tabs.
is circulating through cooling system. Wipe the inner part of the filler neck and examine
the lower inside sealing seat for nicks, cracks, paint,
TESTING COOLING SYSTEM FOR LEAKS dirt and solder residue. Inspect the reserve/overflow
tank tube for internal obstructions. Insert a wire
ULTRAVIOLET LIGHT METHOD through the tube to be sure it is not obstructed.
All Jeep models have a leak detection additive Inspect the cams on the outside part of the filler
added to the cooling system before they leave the fac- neck. If the cams are bent, seating of pressure cap
tory. The additive is highly visible under ultraviolet valve and tester seal will be affected. Replace cap if
light (black light). If the factory original coolant has cams are bent.
been drained, pour one ounce of additive into the Attach pressure tester 7700 (or an equivalent) to
cooling system. The additive is available through the the radiator filler neck (Fig. 19).
parts department. Place the heater control unit in
HEAT position. Start and operate the engine until
the radiator upper hose is warm to the touch. Aim
the commercially available black light tool at the
components to be checked. If leaks are present, the
black light will cause the additive to glow a bright
green color.
The black light can be used along with a pressure
tester to determine if any external leaks exist (Fig.
18).
Fig. 19 Pressurizing System—Typical

Operate the tester pump to apply 124 kPa (18 psi)
pressure to the system. If the hoses enlarge exces-
sively or bulge while testing, replace as necessary.
Observe the gauge pointer and determine the condi-
tion of the cooling system according to the following
criteria:
• Holds Steady: If the pointer remains steady for
two minutes, there are no serious coolant leaks in
the system. However, there could be an internal leak
that does not appear with normal system test pres-
sure. Inspect for interior leakage or do the Internal
Leakage Test. Do this if it is certain that coolant is
being lost and no leaks can be detected.
• Drops Slowly: Shows a small leak or seepage is
occurring. Examine all connections for seepage or
Fig. 18 Leak Detection Using Black Light—Typical slight leakage with a flashlight. Inspect the radiator,
PRESSURE TESTER METHOD hoses, gasket edges and heater. Seal any small leak
The engine should be at the normal operating tem- holes with a Sealer Lubricant or equivalent. Repair
perature. Recheck the system cold if the cause of leak holes and reinspect the system with pressure
coolant loss is not located during warm engine exam- applied.
ination. • Drops Quickly: Shows that a serious leakage is
occurring. Examine the system for serious external
leakage. If no leaks are visible, inspect for internal Drain sufficient coolant to allow for thermostat
leakage. Large radiator leak holes should be repaired removal. Refer to Thermostat Replacement. Discon-
by a reputable radiator repair shop. nect the water pump drive belt.
Disconnect the upper radiator hose from the ther-
INTERNAL LEAKAGE INSPECTION mostat housing. Remove the housing and thermostat.
Remove the oil pan drain plug and drain a small Install the thermostat housing.
amount of engine oil. Coolant, being heavier, will Add coolant to the radiator to bring the level to
drain first, or operate engine to churn oil, then exam- within 6.3 mm (1/4 in) of the top of the thermostat
ine dipstick for water globules. Inspect the transmis- housing.
sion dipstick for water globules. Inspect the
transmission fluid cooler for leakage. Operate the CAUTION: Avoid overheating. Do not operate the
engine without the pressure cap on the radiator until engine for an excessive period of time. Open the
thermostat opens. draincock immediately after the test to eliminate
Attach a Pressure Tester to the filler neck. If pres- boil over of coolant.
sure builds up quickly, a leak exists as result of a
faulty cylinder head gasket or crack in the engine. Start the engine and accelerate rapidly three times
Repair as necessary. (to approximately 3000 rpm) while observing the
coolant. If internal engine combustion gases are leak-
WARNING: DO NOT ALLOW PRESSURE TO ing into the cooling system, bubbles will appear in
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF. the coolant. If bubbles do not appear, there is no
TO RELEASE THE PRESSURE, ROCK THE TESTER internal combustion gas leakage.
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN VISCOUS FAN DRIVE
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
TESTING
If there is no immediate pressure increase, pump If the fan assembly free-wheels without drag (the
the Pressure Tester until the indicated pressure is fan blades will revolve more than five turns when
within the system range. Vibration of the gauge spun by hand), replace the fan drive. This spin test
pointer indicates compression or combustion leakage must be performed when the engine is cool.
into the cooling system. For the following test, the cooling system must be
in good condition. It also will ensure against exces-
WARNING: DO NOT DISCONNECT THE SPARK sively high coolant temperature.
PLUG WIRES WHILE THE ENGINE IS OPERATING.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic (1) Drill a 3.18-mm (1/8-in) diameter hole in the
converter may be damaged. top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
Isolate the compression leak by shorting each (or equivalent). It should have a range of -18° to
spark plug to the cylinder block. The gauge pointer 105°C (0° to 220° F). Insert thermometer through the
should stop or decrease vibration when spark plug hole in the shroud. Be sure that there is adequate
for leaking cylinder is shorted. This happens because clearance from the fan blades.
of the absence of combustion pressure. (3) Connect a tachometer and an engine ignition
timing light (timing light is to be used as a strobe
COMBUSTION LEAKAGE TEST (WITHOUT
light).
PRESSURE TESTER)
(4) Block the air flow through the radiator. Secure
DO NOT WASTE reusable coolant. If the solution
a sheet of plastic in front of the radiator (or air con-
is clean, drain the coolant into a clean container for
ditioner condenser). Use tape at the top to secure the
reuse.
plastic and be sure that the air flow is blocked.
WARNING: DO NOT REMOVE THE CYLINDER (5) Be sure that the air conditioner (if equipped) is
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR turned off.
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
WARNING: USE EXTREME CAUTION WHEN THE HOSE TO DETERMINE WHEN PRESSURE HAS
ENGINE IS OPERATING. DO NOT STAND IN A BEEN RELEASED. WHEN COOLANT AND STEAM
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR STOP BEING PUSHED INTO TANK AND SYSTEM
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO PRESSURE DROPS, REMOVE RADIATOR CAP
NOT WEAR LOOSE CLOTHING. COMPLETELY.
(6) Start the engine and operate at 2400 rpm.

Within ten minutes the air temperature (indicated on PRESSURE TESTING RADIATOR CAP
the dial thermometer) should be up to 88° C (190° F). Remove cap from radiator. Be sure that sealing
Fan drive engagement should have started to occur surfaces are clean. Moisten rubber gasket with water
at between 74° to 82° C (165° to 180° F). Engage- and install the cap on pressure tester (tool 7700 or
ment is distinguishable by a definite increase in fan an equivalent) (Fig. 20).
flow noise (roaring). The timing light also will indi-
cate an increase in the speed of the fan.
(7) When the air temperature reaches 88° C (190°
F), remove the plastic sheet. Fan drive disengage-
ment should have started to occur at between 57° to
79° C (135° to 175° F). A definite decrease of fan
flow noise (roaring) should be noticed. If not, replace
the defective viscous fan drive unit.
RADIATOR CAP-TO-FILLER NECK SEAL—

PRESSURE RELIEF CHECK
With radiator cap installed on filler neck, remove
coolant reserve/overflow tank hose from nipple on
filler neck. Connect a hand operated vacuum pump
to nipple. Operate pump until a reading of 47 to 61
kPa (14 to 18 in. Hg) appears on gauge. If the read-
ing stays steady, or drops slightly and then remains
steady, the pressure valve seal is good. Replace radi-
ator cap if reading does not hold.
WARNING: THE WARNING WORDS —DO NOT

OPEN HOT— ON THE RADIATOR PRESSURE CAP
ARE A SAFETY PRECAUTION. WHEN HOT, PRES- Fig. 20 Pressure Testing Radiator Pressure
SURE BUILDS UP IN COOLING SYSTEM. TO PRE- Cap—Typical
VENT SCALDING OR INJURY, THE RADIATOR CAP
Operate the tester pump and observe the gauge
SHOULD NOT BE REMOVED WHILE THE SYSTEM
pointer at its highest point. The cap release pressure
IS HOT AND/OR UNDER PRESSURE.
should be 97 to 124 kPa (14 to 18 psi). The cap is
There is no need to remove the radiator cap satisfactory when the pressure holds steady. It is also
except for the following purposes: good if it holds pressure within the 97 to 124 kPa (14
• To check and adjust antifreeze freeze point. to 18 psi) range for 30 seconds or more. If the pointer
• To refill system with new antifreeze. drops quickly, replace the cap.
• For conducting service procedures.
CAUTION: Radiator pressure testing tools are very
• When checking for vacuum leaks.
sensitive to small air leaks, which will not cause
WARNING: IF VEHICLE HAS BEEN RUN cooling system problems. A pressure cap that does
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE not have a history of coolant loss should not be
REMOVING RADIATOR CAP. WITH A RAG, replaced just because it leaks slowly when tested
SQUEEZE RADIATOR UPPER HOSE TO CHECK IF with this tool. Add water to tool. Turn tool upside
SYSTEM IS UNDER PRESSURE. PLACE A RAG down and recheck pressure cap to confirm that cap
OVER THE CAP AND WITHOUT PUSHING DOWN, needs replacement.
ROTATE CAP COUNTER-CLOCKWISE TO THE
FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH
OVERFLOW HOSE INTO COOLANT RESERVE/
OVERFLOW TANK. SQUEEZE RADIATOR UPPER
LOW COOLANT LEVEL-AERATION from radiator drain cock. Do this while observing
If the coolant level in radiator drops below top of coolant reserve/overflow system tank. The coolant
radiator core tubes, air will enter cooling system. level in reserve/overflow tank should drop slightly. If
Low coolant level can cause thermostat pellet to be not, inspect for a leak between radiator and coolant
suspended in air instead of coolant. This will cause reserve/overflow system connection. Remove radiator
thermostat to open later, which in turn causes higher cap. The coolant level should be to top of radiator. If
coolant temperature. Air trapped in cooling system not and if coolant level in reserve/overflow tank is at
also reduces amount of coolant circulating in heater ADD mark, check for:
core resulting in low heat output. • An air leak in coolant reserve/overflow tank or
its hose
DEAERATION • An air leak in radiator filler neck
As the engine operates, any air trapped in cooling • Leak in pressure cap seal to radiator filler neck
system gathers under the radiator cap. The next time
the engine is operated, thermal expansion of coolant DRAINING AND FILLING COOLING SYSTEM
will push any trapped air past radiator cap into the
coolant reserve/overflow tank. Here it escapes to the DRAINING COOLING SYSTEM
atmosphere into the tank. When the engine cools
WARNING: DO NOT REMOVE THE CYLINDER
down the coolant, it will be drawn from the reserve/
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
overflow tank into the radiator to replace any
DRAINCOCK WITH SYSTEM HOT AND UNDER
removed air.
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
SERVICE PROCEDURES
ROUTINE COOLANT LEVEL CHECK is clean, drain the coolant into a clean container for
reuse.
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be DRAINING ENTIRE SYSTEM
checked at coolant reserve/overflow tank. Use this procedure if the entire cooling system is to
be drained, such as for engine removal.
The coolant reserve/overflow system provides a (1) DO NOT remove radiator cap first. With engine
quick visual method for determining coolant level cold, raise vehicle on a hoist and locate radiator
without removing radiator pressure cap. With engine draincock.
idling and at normal operating temperature, observe • 4.0L 6-cyl. Engine: Radiator draincock is located
coolant level in reserve/overflow tank. The coolant on the right/lower side of radiator facing to rear of
level should be between ADD and FULL marks. vehicle.
• 5.2L V-8 Engine: Radiator draincock is located
ADDING ADDITIONAL COOLANT on the left/lower side of radiator facing to rear of
Do not remove radiator cap to add coolant to vehicle.
system. When adding coolant to maintain correct (2) Attach one end of a hose to the draincock. Put
level, do so at coolant reserve/overflow tank. Use a the other end into a clean container. Open draincock
50/50 mixture of ethylene-glycol antifreeze and low and drain coolant from radiator. This will empty the
mineral content water. Remove radiator cap only for coolant reserve/overflow tank. The coolant does not
testing or when refilling system after service. Remov- have to be removed from the tank unless the system
ing cap unnecessarily can cause loss of coolant and is being refilled with a fresh mixture. When tank is
allow air to enter system, which produces corrosion. empty, remove radiator cap and continue draining
cooling system.
COOLANT LEVEL CHECK—SERVICE To drain the 4.0L 6-cylinder engine of coolant,
The cooling system is closed and designed to main- remove the cylinder block drain plug located on the
tain coolant level to top of radiator. side of cylinder block (Fig. 21).
To drain the 5.2L V-8 engine of coolant, remove the
WARNING: DO NOT OPEN RADIATOR DRAINCOCK cylinder block drain plugs located on the sides of cyl-
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT inder block above the oil pan rail (Fig. 22).
AND COOLING SYSTEM IS UNDER PRESSURE.
PARTIAL DRAINING
When vehicle servicing requires a coolant level Use this procedure if the coolant is to be partially
check in radiator, drain several ounces of coolant drained, such as for engine thermostat removal.
SERVICE PROCEDURES (Continued)
(2) Fill system using a 50/50 mixture of ethylene-
glycol anifreeze and low mineral conent water. Fill
radiator to top and install radiator cap. Add suffi-
cient coolant to the reserve/overflow tank to raise
level to FULL mark.
(3) With heater control unit in the HEAT position,
operate engine with radiator cap in place.
(4) After engine has reached normal operating
temperature, shut engine off and allow it to cool.
When engine is cooling down, coolant will be drawn
into the radiator from the reserve/overflow tank.
(5) Add coolant to reserve/overflow tank as neces-
sary. Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion. To purge the cooling system of all air,
this heat up/cool down cycle (adding coolant to cold
engine) must be performed three times. Add neces-
sary coolant to raise tank level to the FULL mark
after each cool down period.
Fig. 21 Drain Plug—4.0L 6-Cylinder Engine COOLING SYSTEM CLEANING/REVERSE FLUSHING

CAUTION: The cooling system normally operates
at 97 to 124 kPa (14 to 18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
CLEANING
Drain cooling system and refill with water. Run
engine with radiator cap installed until upper radia-
tor hose is hot. Stop engine and drain water from
system. If water is dirty, fill system with water, run
engine and drain system. Repeat until water drains
clean.
REVERSE FLUSHING
Reverse flushing of the cooling system is the forc-
ing of water through the cooling system. This is done
Fig. 22 Drain Plugs—5.2L V-8 Engine using air pressure in the opposite direction of normal
(1) With engine cold, slowly remove the radiator coolant flow. It is usually only necessary with very
cap. Raise vehicle on a hoist and locate radiator dirty systems with evidence of partial plugging.
draincock.
• 4.0L Engine: Radiator draincock is located on REVERSE FLUSHING RADIATOR
the right/lower side of radiator facing to rear of vehi- Disconnect the radiator hoses from the radiator fit-
cle. tings. Attach a section of radiator hose to the radia-
• 5.2L Engine: Radiator draincock is located on tor bottom outlet fitting and insert the flushing gun.
the left/lower side of radiator facing to rear of vehi- Connect a water supply hose and air supply hose to
cle. the flushing gun.
(2) Attach one end of a hose to the draincock. Put
CAUTION: The cooling system normally operates
the other end into a clean container.
at 97 to 124 kPa (14 to 18 psi) pressure. Exceeding
(3) Open draincock and drain desired amount of
this pressure may damage the radiator or hoses.
coolant from radiator.
Allow the radiator to fill with water. When radiator
REFILLING COOLING SYSTEM
is filled, apply air in short blasts allowing radiator to
(1) Tighten the radiator draincock and the cylinder
refill between blasts. Continue this reverse flushing
block drain plug(s) (if removed).
until clean water flows out through rear of radiator
SERVICE PROCEDURES (Continued)
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
ment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE

Drain the cooling system. Remove the thermostat
housing and thermostat. Install the thermostat hous-
ing. Disconnect the radiator upper hose from the
radiator and attach the flushing gun to the hose. Dis-
connect the radiator lower hose from the water
pump. Attach a lead away hose to the water pump
inlet fitting.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
water. When the engine is filled, apply air in short
blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
Fig. 23 Oil Cooler Mounting Brackets—Typical
supply hose and air supply hose. Remove the thermo-
stat housing and install thermostat. Install the ther-
mostat housing with a replacement gasket. Refer to
Thermostat Replacement. Connect the radiator
hoses. Refill the cooling system with the correct anti-
freeze/water mixture.
CHEMICAL CLEANING
In some instances, use a radiator cleaner (Mopar
Radiator Kleen or equivalent) before flushing. This
will soften scale and other deposits and aid the flush-
ing operation.
CAUTION: Be sure instructions on the container

are followed.
REMOVAL AND INSTALLATION

TRANSMISSION OIL COOLER—AUXILIARY
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Remove the grill. Refer to Group 23, Body. Fig. 24 Oil Cooler Hoses—Typical
(3) Remove the bumper fascia. Refer to Group 23,
(9) Position the cooler to gain access to lower hose.
Body.
The cooler lines are routed through a rubber seal
(4) Remove the grill opening reinforcement panel.
located on the side of radiator. Be careful not to cut
Refer to Group 23, Body.
or tear this seal when positioning cooler for lower
(5) Remove two bracket bolts and three brace bolts
hose removal.
(Fig. 23).
(10) Remove lower hose clamp and hose from
(6) Remove the retaining clip from the cooler lines
cooler.
(Fig. 23).
(11) Remove cooler from vehicle.
(7) Place a drain pan under the cooler.
(8) Disconnect the upper hose clamp at cooler line INSTALLATION
(Fig. 24). Separate the line from the rubber hose. (1) Position cooler to vehicle.
REMOVAL AND INSTALLATION (Continued)
(2) Install lower hose and hose clamp to cooler.
Hose clamp screws must be facing towards rear of
vehicle. Tighten clamp to 2 N·m (18 in. lbs.) torque.
(3) Install upper hose and hose clamp at cooler.
Hose clamp screws must be facing towards rear of
vehicle. Tighten clamp to 2 N·m (18 in. lbs.) torque.
(4) Install brace and mounting bracket bolts (Fig.
23).
(5) Connect negative battery cable to battery.
(6) Add necessary transmission fluid. Refer to
Group 21, Transmissions. Start engine and check for
leaks.
(7) Install grill opening reinforcement panel,
bumper fascia and grill. Refer to Group 23, Body.
WATER PUMP 4.0L ENGINE

CAUTION: If the water pump is replaced because
of mechanical damage, the fan blades and viscous
fan drive should also be inspected. These compo-
nents could have been damaged due to excessive
vibration.
Fig. 25 Reverse Rotating Water Pump—Typical
(5) Vehicles with 4.0L 6-cylinder engine with-
REMOVAL out A/C or heavy duty cooling system:
The water pump can be removed without discharg- (6) Loosen (but do not remove at this time) the
ing the air conditioning system (if equipped). four fan hub-to-water pump pulley mounting nuts
(Fig. 27).
CAUTION: The 4.0L engine has a reverse (counter-
clockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 25) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.
The water pump impeller is pressed on the rear of

the pump shaft and bearing assembly. The water
pump is serviced only as a complete assembly.
WARNING: DO NOT REMOVE THE BLOCK DRAIN

PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Fig. 26 Water Pump Pulley Bolts
NOTE: The engine accessory drive belt must be
is clean, drain coolant into a clean container for
removed prior to removing the fan (if installed at
reuse.
pump) or fan pulley.
(2) Drain the cooling system. (7) Remove engine drive belt.
(3) Vehicles with 4.0L 6-cylinder engine (8) Remove power steering pump (Fig. 28), refer to
equipped with A/C or heavy duty cooling sys- Group 19 Steering.
tem:
(4) Loosen (but do not remove at this time) the
four water pump pulley-to-water pump hub mounting
bolts (Fig. 26).
Fig. 29 Hose Clamp Tool—Typical

CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 30). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
Fig. 27 Fan Mounting Nuts (9) Remove lower radiator hose from water pump.
WARNING: CONSTANT TENSION HOSE CLAMPS Remove heater hose from water pump fitting.
ARE USED ON MOST COOLING SYSTEM HOSES. (10) Remove four nuts or bolts previously loosened
WHEN REMOVING OR INSTALLING, USE ONLY and remove the fan blade assembly and pulley (if fan
TOOLS DESIGNED FOR SERVICING THIS TYPE OF is installed at pump), or remove the pulley from the
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER vehicle.
6094) (Fig. 29) SNAP-ON CLAMP TOOL (NUMBER (11) After removing fan blade/viscous fan drive
HPC-20) MAY BE USED FOR LARGER CLAMPS. assembly, do not place thermal viscous fan drive in
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- horizontal position. If stored horizontally, silicone
ING CONSTANT TENSION CLAMPS. fluid in viscous fan drive could drain into its bearing
assembly and contaminate lubricant.
Fig. 28 Power Steering Pump Attachment

(13) If pump is to be replaced, the heater hose fit-
ting must be removed. Note position of fitting before
removal.
INSTALLATION
(1) If pump is being replaced, install the heater
hose fitting to the pump. Use a sealant on the fitting
such as Mopary Thread Sealant With Teflon. Refer
to the directions on the package.
(2) Clean the gasket mating surfaces. If the origi-
nal pump is used, remove any deposits or other for-
eign material. Inspect the cylinder block and water
pump mating surfaces for erosion or damage from
cavitation.
(3) Install the gasket and water pump. The sili-
cone bead on the gasket should be facing the water
pump. Also, the gasket is installed dry. Tighten
mounting bolts to 30 N·m (22 ft. lbs.) torque. Rotate
the shaft by hand to be sure it turns freely.
(4) Connect the radiator and heater hoses to the
water pump.
(5) Position water pump pulley to water pump
Fig. 30 Clamp Number/Letter Location hub.
(12) Remove the four pump mounting bolts (Fig. (6) If equipped with a water pump mounted fan,
31) and remove pump from vehicle. Discard old gas- install fan and four nuts to water pump hub. If not
ket. Note that one of the four bolts is longer than the equipped with a water pump mounted fan, install
other bolts. four pump hub bolts. Tighten bolts (or nuts) to 27
N·m (20 ft. lbs.) torque.
(7) Install power steering pump.
CAUTION: When installing the serpentine engine

accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installtion in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
(8) Adjust accessory drive belt, refer to Accessory

Drive Belt removal and installation in this group.
(9) Fill cooling system with coolant and check for
leaks. Refer to Refilling Cooling System in this
group.
(10) Connect battery cable to battery.
(11) Start and warm the engine. Check for leaks.
WATER PUMP 5.2L ENGINE

The water pump on 5.2L engines is bolted directly
to the engine timing chain case/cover.
A gasket is used as a seal between the water pump
and timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage, or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for
fatigue cracks, loose blades, or loose rivets that could
Fig. 31 Water Pump Remove/Install—Typical have resulted from excessive vibration. Replace fan if
any of these conditions are found. Also check condi- ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
tion of the thermal viscous fan drive. Refer to Viscous ING CONSTANT TENSION CLAMPS.
Fan Drive in this group.
The water pump can be removed without discharg-
ing the air conditioning system (if equipped). CAUTION: A number or letter is stamped into the
REMOVAL replacement is necessary, use only an original
(1) Disconnect negative battery cable from battery. equipment clamp with matching number or letter.
(2) Drain cooling system. Refer to Draining Cool-
ing System in this group. (4) If water pump is being replaced, do not unbolt
Do not waste reusable coolant. If solution is clean, fan blade assembly (Fig. 32) from thermal viscous
drain coolant into a clean container for reuse. fan drive.
(3) The thermal viscous fan drive is attached (5) Remove two fan shroud-to-radiator nuts (Fig.
(threaded) to the water pump hub shaft (Fig. 32). 33). Do not attempt to remove fan shroud at this
Remove fan/viscous fan drive assembly from water time.
pump by turning mounting nut counterclockwise as
viewed from front. Threads on viscous fan drive are
RIGHT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between water pump pulley bolts (Fig.
32) to prevent pulley from rotating. Do not attempt
to remove fan/viscous fan drive assembly from vehi-
cle at this time.
Fig. 33 Fan Shroud Nuts

(6) Remove fan shroud and fan blade/viscous fan
drive assembly from vehicle as a complete unit.
(7) After removing fan blade/viscous fan drive
assembly, do not place thermal viscous fan drive in
horizontal position. If stored horizontally, silicone
fluid in viscous fan drive could drain into its bearing
(8) Do not remove water pump pulley bolts at this
Fig. 32 Fan Blade and Viscous Fan Drive—5.2L time.
Engine (9) Remove accessory drive belt as follows: The
WARNING: CONSTANT TENSION HOSE CLAMPS drive belt is equipped with a spring loaded automatic
ARE USED ON MOST COOLING SYSTEM HOSES. belt tensioner (Fig. 34). Relax tension from belt by
WHEN REMOVING OR INSTALLING, USE ONLY rotating tensioner clockwise (as viewed from front)
TOOLS DESIGNED FOR SERVICING THIS TYPE OF (Fig. 34). When all belt tension has been relaxed,
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER remove accessory drive belt.
6094) (Fig. 29). SNAP-ON CLAMP TOOL (NUMBER (10) Remove four water pump pulley-to-water
HPC-20) MAY BE USED FOR LARGER CLAMPS. pump hub bolts (Fig. 32) and remove pulley from
vehicle.
Fig. 36 Water Pump Bolts—5.2L Engine—Typical

(15) Loosen clamp at water pump end of bypass
hose (Fig. 32). Slip bypass hose from water pump
while removing pump from vehicle. Discard old gas-
ket.
Fig. 34 Belt Tensioner Assembly—5.2L Engine CAUTION: Do not pry water pump at timing chain
(11) Remove lower radiator hose clamp and remove case/cover. The machined surfaces may be dam-
lower hose at water pump. aged resulting in leaks.
(12) Remove heater hose clamp (Fig. 35) and
heater hose from heater hose coolant return tube.
INSTALLATION
(13) Loosen heater hose coolant return tube
(1) Clean gasket mating surfaces.
mounting bolt and nut (Fig. 35) and remove tube
(2) Using a new gasket, install water pump to
from water pump. Discard the old tube o-ring.
engine as follows: Guide water pump nipple into
bypass hose as pump is being installed. Install water
pump bolts (Fig. 36). Tighten water pump mounting
bolts to 40 N·m (30 ft. lbs.) torque.
(3) Position bypass hose clamp to bypass hose.
(4) Spin water pump to be sure that pump impel-
ler does not rub against timing chain case/cover.
(5) Install a new o-ring to the heater hose coolant
return tube (Fig. 35). Coat the new o-ring with anti-
freeze before installation.
(6) Install coolant return tube to engine (Fig. 35).
Be sure the slot in tube bracket is bottomed to the
mounting bolt. This will properly position return
tube.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to coolant
return tube.
(9) Install water pump pulley. Tighten bolts to 27
N·m (20 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 32) to prevent
pulley from rotating.
(10) Relax tension from belt tensioner (Fig. 34).
Install drive belt.
Fig. 35 Coolant Return Tube—5.2L Engine
(14) Remove seven water pump mounting bolts
(Fig. 36).
CAUTION: When installing the serpentine acces- Do not waste reusable coolant. If the solution is
sory drive belt, belt must be routed correctly. If not, clean, drain the coolant into a clean container for
engine may overheat due to water pump rotating in reuse.
wrong direction. Refer to (Fig. 37) for correct belt (1) Drain the coolant from the radiator until the
routing. Or, refer to the Belt Routing Label located level is below the thermostat housing.
in the engine compartment. The correct belt with
correct length must be used. WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 53). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.

(2) Remove radiator upper hose and heater hose at

thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 38).
Discard old gasket.
(5) Clean the gasket mating surfaces.
Fig. 37 Belt Routing—5.2L Engine
(11) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(12) Be sure the upper and lower portions of the
fan shroud are firmly connected. All air must flow
through the radiator.
(13) Install two fan shroud-to-radiator nuts (Fig.
33).
(14) Be sure of at least 25 mm (1.0 inches)
between tips of fan blades and fan shroud.
(15) Install fan blade/viscous fan drive assembly to
water pump shaft.
(16) Fill cooling system. Refer to Refilling the
Cooling System in this group.
(17) Connect negative battery cable.
THERMOSTAT 4.0L ENGINE

REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR

DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR. Fig. 38 Thermostat Removal/Installation—4.0L
Engine
INSTALLATION THERMOSTAT 5.2L ENGINE
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the REMOVAL
engine. All thermostats are marked on the outer
flange to indicate the proper installed position. WARNING: DO NOT LOOSEN RADIATOR DRAIN-
(a) Observe the recess groove in the engine cyl- COCK WITH SYSTEM HOT AND PRESSURIZED.
inder head (Fig. 39). SERIOUS BURNS FROM COOLANT CAN OCCUR.
(b) Position thermostat in groove with arrow and
air bleed hole on outer flange pointing up. Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
Factory installed thermostat housings on 5.2L
engines are installed on a gasket with an anti-stick
coating. This will aid in gasket removal and clean-up.
(2) Drain cooling system until coolant level is
below thermostat. Refer to Draining Cooling System
in this group.
(3) Air Conditioned vehicles: Remove support
bracket (generator mounting bracket-to-intake mani-
fold) located near rear of generator (Fig. 40).
Fig. 39 Thermostat Recess—4.0L Engine

(2) Install replacement gasket and thermostat
housing.
CAUTION: Tightening the thermostat housing

unevenly or with the thermostat out of its recess,
may result in a cracked housing.
(3) Tighten the housing bolts to 22 N·m (16 ft. lbs.)

torque.
(4) Install hoses to thermostat housing.
(5) Install electrical connector to coolant tempera-
ture sensor.
(6) Be sure that the radiator draincock is tightly
closed. Fill the cooling system to the correct level Fig. 40 Generator Support Bracket—5.2L Engine
with the required coolant mixture. Refer to Refilling (4) On air conditioning equipped vehicles, the gen-
Cooling System in this group. erator must be partially removed.
(7) Start and warm the engine. Check for leaks. (a) Remove generator drive belt as follows: Drive
belts on the 5.2L engine are equipped with a
spring loaded automatic belt tensioner (Fig. 41).
(b) Attach a socket/wrench to pulley mounting
bolt of automatic belt tensioner (Fig. 41).
(c) Rotate tensioner assembly clockwise (as
viewed from front) until tension has been relieved
from belt.
(d) Remove belt from vehicle.
(e) Remove two generator mounting bolts. Do
not remove any wiring at generator. If equipped
with 4WD, unplug 4WD indicator lamp wiring har-
ness (located near rear of generator).
(f) Remove generator. Position generator to gain
access for thermostat gasket removal.
Fig. 42 Thermostat—5.2L Engine
Fig. 41 Automatic Belt Tensioner—5.2L Engine

(5) Remove upper radiator hose clamp (Fig. 53)
and upper radiator hose at thermostat housing.
(6) Position wiring harness (behind thermostat
housing) to gain access to thermostat housing.
(7) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 42).
Discard old gasket.
INSTALLATION
(1) Clean mating areas of intake manifold and
thermostat housing.
(2) Install thermostat (spring side down) into
recessed machined groove on intake manifold (Fig.
42).
(3) Install gasket on intake manifold and over
thermostat (Fig. 42). Fig. 43 Thermostat Position—5.2L Engine
(4) Position thermostat housing to intake manifold.
Note the word FRONT stamped on housing (Fig. 43). in intake manifold. If not, it may result in a cracked
For adequate clearance, this must be placed towards housing, damaged intake manifold threads or cool-
front of vehicle. The housing is slightly angled for- ant leak.
ward after installation to intake manifold.
(6) Install upper radiator hose to thermostat hous-
(5) Install two housing-to-intake manifold bolts.
ing.
Tighten bolts to 23 N·m (200 in. lbs.) torque.
(7) Air Conditioned vehicles:
CAUTION: Housing must be tightened evenly and
thermostat must be centered into recessed groove
CAUTION: When installing the serpentine acces- DRAINCOCK WITH THE SYSTEM HOT AND UNDER
sory drive belt, belt must be routed correctly. If not, PRESSURE. SERIOUS BURNS FROM COOLANT
engine may overheat due to water pump rotating in CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
wrong direction. Refer to (Fig. 44) for correct 5.2L ING IN THIS GROUP.
engine belt routing. Or, refer to the Belt Routing
Label located in the engine compartment. The cor- Do not waste reusable coolant. If the solution is
rect belt with correct length must be used. clean, drain the coolant into a clean container for
reuse.
(a) Install generator. Tighten bolts to 41 N·m (30
ft. lbs.) torque. WARNING: CONSTANT TENSION HOSE CLAMPS
(b) Install support bracket (generator mounting ARE USED ON MOST COOLING SYSTEM HOSES.
bracket-to-intake manifold) (Fig. 40). Tighten bolts WHEN REMOVING OR INSTALLING, USE ONLY
to 54 N·m (40 ft. lbs.) torque. TOOLS DESIGNED FOR SERVICING THIS TYPE OF
(c) Position drive belt over all pulleys except CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
idler pulley (located between generator and A/C 6094) (Fig. 45). SNAP-ON CLAMP TOOL (NUMBER
compressor). HPC-20) MAY BE USED FOR LARGER CLAMPS.
(d) Attach a socket/wrench to pulley mounting ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
bolt of automatic belt tensioner (Fig. 41). ING CONSTANT TENSION CLAMPS.
(e) Rotate socket/wrench clockwise. Place belt
over idler pulley. Let tensioner rotate back into
place. Remove wrench. Be sure belt is properly
seated on all pulleys.
Fig. 45 Hose Clamp Tool—Typical

CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
Fig. 44 Belt Routing—5.2L Engine air seals (Fig. 47). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
(8) Fill cooling system. Refer to Refilling Cooling
To prevent overheating, these seals must be
System in this group.
installed to their original positions.
(9) Connect negative battery cable to battery.
(10) Start and warm the engine. Check for leaks. (1) Disconnect the negative battery cable at bat-
tery.
RADIATOR (2) Observe the previous WARNINGS and CAU-
TIONS.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER

BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
(4) 4.0L Engine: Remove the four fan hub-to-wa-
ter pump pulley mounting nuts (Fig. 48). Carefully
remove the fan assembly from the water pump pulley
and position to center of fan shroud. Fan belt
removal is not necessary as the water pump studs
will hold the pump pulley in position.
(5) Do not remove fan/viscous fan drive assembly
from vehicle at this time.
(6) 5.2L Engine: The thermal viscous fan drive is
attached (threaded) to the water pump hub shaft
(Fig. 49). Remove fan/viscous fan drive assembly
from water pump by turning mounting nut counter-
clockwise as viewed from front. Threads on viscous
fan drive are RIGHT HAND. A Snap-On 36 MM Fan
Wrench (number SP346 from Snap-On Cummins Die-
sel Tool Set number 2017DSP) can be used. Place a
bar or screwdriver between water pump pulley bolts
(Fig. 49) to prevent pulley from rotating. Drive belt
removal is not necessary for removal of fan drive.
(7) Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
(8) Remove the two fan shroud-to-upper radiator
Fig. 46 Clamp Number/Letter Location crossmember mounting nuts (Fig. 50).
(3) Drain coolant from radiator. Refer to Draining (9) Remove the fan assembly and fan shroud (as
Cooling System in this group. one unit) from vehicle.
Fig. 47 Air Seals—Typical

Fig. 48 Fan Mounting Nuts—4.0L 6-Cyl. Engine Fig. 50 Radiator and A/C Condenser Mounting
holes. Before removal, mark the original position of
the crossmember.
Fig. 49 Fan Blade and Viscous Fan Drive—5.2L V-8

Engine Fig. 51 Radiator Upper Crossmember—Typical
(10) Special quick-connect fittings are used to join (12) Eight clips are used to retain a rubber seal
the transmission cooling lines to the radiator. (Fig. 51) to the body and upper radiator crossmem-
Removal procedures are different between the 4.0L ber. Gently pry up the outboard clips (two per side)
and 5.2L engine. Disconnect the cooling lines from until rubber seal can be removed. Do not remove the
the radiator. Refer to Group 21 for transmission cool- clips entirely. Fold back the seal on both sides for
ing line removal and installation. access to (the hidden) grille opening reinforcement
(11) The radiator upper crossmember (Fig. 51) can mounting bolts (Fig. 51). Remove these two bolts.
be adjusted left or right through the use of slotted (13) Remove the grill. Refer to group 23, Body.
(14) Remove the upper brace bolt from each of the
two radiator braces (Fig. 50).
(15) Remove the two crossmember-to-radiator
mounting nuts (Fig. 51).
(16) Working through grill opening, remove the
lower bracket bolt securing lower part of hood latch
support bracket to lower frame crossmember (Fig.
50).
(17) Remove the remaining four bolts securing the
radiator upper crossmember to the body. Do not
remove the hood latch or hood latch cable from the
crossmember. Lift the crossmember straight up and
lay to the side.
(18) Equipped with air conditioning: Remove the
two A/C condenser-to-radiator mounting bolts (Fig.
50). These two bolts are also used to retain the side
mounted rubber air seals (Fig. 47). These seals are
compressed between the A/C condenser and the radi-
ator. The lower part of the air seals are compressed
between the radiator and the A/C condenser mount-
ing brackets (Fig. 52).
(19) Not equipped with air conditioning: Remove
the two bolts retaining the side mounted rubber air
seals (Fig. 47) to the radiator. The lower part of the
air seals are compressed between the radiator and
the radiator lower crossmember.
CAUTION: Note the location of all rubber air seals

(Fig. 47). To prevent overheating, they must be Fig. 52 Radiator Alignment Dowels
installed back to their original positions. air seal on the left side of radiator. Do not cut or tear
this seal.
(20) Disconnect the coolant reserve/overflow tank (26) Gently lift up and remove radiator from vehi-
hose (Fig. 51) at radiator. cle. Be careful not to scrape the radiator fins against
(21) Remove upper radiator hose at radiator. A any other component. Also be careful not to disturb
special clamp tool (Fig. 45) must be used to remove the air conditioning condenser (if equipped).
the constant tension hose clamps.
(22) 4.0L Engine Only: Remove the lower radiator INSTALLATION
hose at the water pump end.
(23) To gain access to lower radiator hose clamp at CAUTION: Before installing the radiator or A/C
radiator, gently lift the radiator a slight amount. condenser, be sure the radiator-to-body and radia-
Remove hose clamp and hose. tor-to-A/C condenser rubber air seals (Fig. 47) are
(24) The lower part of radiator is equipped with properly fastened to their original positions. These
two alignment dowel pins (Fig. 50) (Fig. 52). They are used at the top, bottom and sides of the radia-
are located on the bottom of radiator tank and fit tor and A/C condenser. To prevent overheating,
into rubber grommets. These rubber grommets are these seals must be installed to their original posi-
pressed into the radiator lower crossmember. tions.
WARNING: THE AIR CONDITIONING SYSTEM (IF (1) Equipped with air conditioning: Gently lower
EQUIPPED) IS UNDER A CONSTANT PRESSURE the radiator into the vehicle. Guide the two radiator
EVEN WITH THE ENGINE OFF. REFER TO REFRIG- alignment dowels through the holes in the rubber air
ERANT WARNINGS IN GROUP 24, HEATING AND seals first and then through the A/C support brackets
AIR CONDITIONING BEFORE HANDLING ANY AIR (Fig. 52). Continue to guide the alignment dowels
CONDITIONING COMPONENT. into the rubber grommets located in lower radiator
crossmember (Fig. 52). The holes in the L-shaped
(25) If equipped with an auxiliary automatic trans- brackets (located on bottom of A/C condenser) must
mission oil cooler, use caution when removing radia- be positioned between bottom of rubber air seals and
tor. The oil cooler lines are routed through a rubber top of rubber grommets.
(2) Not equipped with air conditioning: Gently (20) 4.0L Engine: Install the four nuts securing
lower the radiator into the vehicle. Guide the two the fan assembly to the water pump (Fig. 48).
radiator alignment dowels through the holes in the Tighten nuts to 27 N·m (20 ft. lbs.) torque.
rubber air seals. Continue to guide the alignment (21) 5.2L Engine: Install the fan/viscous fan drive
dowels into the rubber grommets located in lower assembly to the water pump.
radiator crossmember. (22) Rotate the fan blades (by hand) and check for
(3) Connect the lower radiator hose and hose interference at fan shroud.
clamp to radiator. (23) Be sure of at least 25 mm (1.0 inches)
between tips of fan blades and fan shroud.
CAUTION: The tangs on the hose clamp must be (24) Fill cooling system. Refer to Refilling Cooling
positioned straight down. System in this group.
(25) Connect battery cable at battery.
(4) 4.0L Engine: Connect the lower radiator hose (26) Start and warm engine. Check for leaks.
at the water pump.
(5) Connect the upper radiator hose at the radia- WATER PUMP BYPASS HOSE
tor.
(6) Equipped with air conditioning: Install the two WITHOUT AIR CONDITIONING
A/C condenser- to-radiator mounting bolts (Fig. 50).
These two bolts are also used to retain the rubber air REMOVAL
seal (Fig. 47) to the sides of radiator. (1) Partially drain cooling system. Refer to Drain-
(7) Not equipped with A/C: Install the two bolts ing Cooling System in this group.
retaining the rubber air seal (Fig. 47) to sides of radi- (2) Do not waste reusable coolant. If solution is
ator. clean, drain coolant into a clean container for reuse.
(8) Install coolant reserve/overflow tank hose at
radiator. WARNING: CONSTANT TENSION HOSE CLAMPS
(9) If radiator-to-upper crossmember rubber isola- ARE USED ON MOST COOLING SYSTEM HOSES.
tors were removed from radiator, install them. WHEN REMOVING OR INSTALLING, USE ONLY
Tighten mounting nuts to 3 N·m (24-36 in. lbs.) TOOLS DESIGNED FOR SERVICING THIS TYPE OF
torque. Position upper radiator crossmember to radi- CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
ator. 6094) (Fig. 53). SNAP-ON CLAMP TOOL (NUMBER
(10) Working through grill opening, install and HPC-20) MAY BE USED FOR LARGER CLAMPS.
tighten the hood latch support bracket-to-lower frame ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
crossmember bolt (Fig. 50). ING CONSTANT TENSION CLAMPS.
(11) Install the four bolts securing the radiator
upper crossmember to the body (Fig. 51).
(12) Install two nuts securing the radiator to the CAUTION: A number or letter is stamped into the
upper radiator crossmember (Fig. 51). Tighten nuts tongue of constant tension clamps (Fig. 54). If
to 2 N·m (18-21 in. lbs.) torque. replacement is necessary, use only an original
(13) Install the upper bolt to each radiator brace equipment clamp with matching number or letter.
(Fig. 50).
(14) Install the grill. Refer to group 23, Body.
(15) Install the rubber seal (Fig. 51) to the four
(outer) seal mounting clips on vehicle body. Press
down on clips until seated.
(16) Install the transmission cooler lines to radia-
tor. Refer to Group 21 for installation.
(17) Position the fan assembly and fan shroud (as
one unit) to the vehicle.
(18) Position fan shroud to radiator. Be sure the
alignment tabs at the lower part of shroud are placed
into the slots near lower part of radiator.
Be sure the upper and lower portions of the fan
shroud are firmly connected. All air must flow
(19) Install the two nuts securing the fan shroud
to the upper radiator crossmember (Fig. 50). Fig. 53 Hose Clamp Tool—Typical
Fig. 54 Clamp Number/Letter Location Fig. 55 Generator and A/C Compressor Mounting
(3) Loosen both bypass hose clamps (Fig. 53) and Bracket—5.2L Engine
position to center of hose. Remove hose from vehicle. (3) Remove upper radiator hose clamp (Fig. 53)
and hose at radiator.
INSTALLATION
(4) Unplug wiring harness from A/C compressor.
(1) Position bypass hose clamps (Fig. 53) to center
(5) Remove air duct at throttle body.
of hose.
(6) Disconnect A/C lines from clip at intake mani-
(2) Install bypass hose to engine.
fold.
(3) Secure both hose clamps (Fig. 53).
(7) Remove heater hose coolant return tube mount-
(4) Fill cooling system. Refer to Refilling the Cool-
ing bolt and nut (Fig. 56). Remove tube from engine
ing System in this group.
and discard the old tube o-ring.
WITH AIR CONDITIONING
REMOVAL
If equipped with A/C, the generator and A/C com-
pressor along with their common mounting bracket
(Fig. 55) must be partially removed. Removing gener-
ator or A/C compressor from their mounting bracket
is not necessary. Also, discharging A/C system is not
necessary. Do not remove any refrigerant lines from
A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRES-

SURE EVEN WITH ENGINE OFF. REFER TO
REFRIGERANT WARNINGS IN GROUP 24, HEATING
AND AIR CONDITIONING.
(1) Disconnect negative battery cable from battery.

(2) Partially drain cooling system. Refer to Drain-
ing Cooling System in this group.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
Fig. 56 Coolant Return Tube—5.2L Engine
(8) Remove accessory drive belt as follows: The 55) to 54 N·m (40 ft. lbs.) torque. Tighten bolts (num-
drive belt is equipped with a spring loaded automatic ber 3) (Fig. 55) to 40 N·m (30 ft. lbs.) torque.
belt tensioner (Fig. 57). Relax tension from belt by (5) Install a new o-ring to the heater hose coolant
rotating tensioner clockwise (as viewed from front) return tube (Fig. 56). Coat the new o-ring with anti-
(Fig. 57). When all belt tension has been relaxed, freeze before installation.
remove accessory drive belt. (6) Install coolant return tube to engine (Fig. 56).
Be sure the slot in tube bracket is bottomed to the
mounting bolt. This will properly position return
tube.
(7) Connect throttle body control cables.
(8) Install oil dipstick mounting bolt.
(9) Install idler pulley. Tighten pulley bolt to 54
N·m (40 ft. lbs.) torque.
(10) Relax tension from belt tensioner (Fig. 57).
Install drive belt.
CAUTION: When installing serpentine accessory

drive belt, belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 58) for correct belt
routing. Or, refer to the Belt Routing Label located
in the engine compartment. The correct belt with
correct length must be used.
Fig. 57 Belt Tensioner Assembly—5.2L Engine

(9) The drive belt idler pulley must be removed to
gain access to one of A/C compressor/generator
bracket mounting bolts. Remove idler pulley bolt and
remove idler pulley (Fig. 55).
(10) Remove oil dipstick tube mounting bolt at side
of A/C- generator mounting bracket.
(11) Disconnect speed control cable and throttle
cable at throttle body. Refer to Accelerator Pedal and
Throttle Cable in Group 14, Fuel System for throttle
cable removal and installation. Refer to Group 8H for
removal and installation of speed control cable.
(12) Remove bracket-to-intake manifold bolts
(number 1 and 2) (Fig. 55).
(13) Remove bracket bolts (Fig. 55).
(14) Lift and position generator and A/C compres-
sor (along with their common mounting bracket) to
gain access to bypass hose. A block of wood may be
used to hold assembly in position. (11) Install air duct to throttle body.
(15) Loosen and position both hose clamps to cen- (12) Install upper radiator hose to radiator.
ter of bypass hose. Remove hose from vehicle. (13) Connect wiring harness to A/C compressor.
(14) Connect A/C lines to clip at intake manifold.
INSTALLATION (15) Fill cooling system. Refer to Refilling the
(1) Position bypass hose clamps to center of hose. Cooling System in this group.
(2) Install bypass hose to engine. (16) Start and warm the engine. Check for leaks.
(3) Secure both hose clamps (Fig. 53).
(4) Install generator-A/C mounting bracket assem-
bly to engine. Tighten bolts (number 1 and 2) (Fig.
ENGINE BLOCK HEATER
REMOVAL
(2) Drain coolant from radiator. Refer to Draining
Cooling System in this group.
(3) Raise vehicle.
(4) Remove engine cylinder block drain plug(s)
located on the sides of cylinder block above the oil
pan rail (Fig. 59) (Fig. 60).
Fig. 61 Block Heater—4.0L Engine
Fig. 59 Drain Plug—4.0L 6-Cylinder Engine
Fig. 62 Block Heater—5.2L Engine

INSTALLATION
(1) Thoroughly clean cylinder block core hole and
block heater seat.
(2) Insert block heater assembly with element loop
pointing down.
(3) With block heater fully seated, tighten center
screw to 2 N·m (17 in. lbs.) torque.
(4) Fill cooling system with recommended coolant.
Refer to Refilling Cooling System section in this
Fig. 60 Drain Plugs—5.2L V-8 Engine
group.
(5) Remove power cord from block heater (Fig. 61) (5) Start and warm the engine. Check for leaks.
(Fig. 62).
(6) Loosen screw at center of block heater. Remove
heater assembly.
BELT REPLACEMENT/ADJUSTMENT
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
4.0L ENGINE
REMOVAL
Belt tension is adjusted at the power steering
pump bracket and idler pulley assembly.
(2) Loosen belt tension at power steering pump
bracket and idler pulley (Fig. 63).
(3) Remove belt.
INSTALLATION
(1) Check condition of all pulleys. 5.2L Engine
Drive belts on the 5.2L engine are equipped with a
CAUTION: When installing the serpentine acces- spring loaded automatic belt tensioner (Fig. 65).
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water CAUTION: Do not attempt to check belt tension
pump rotating in the wrong direction (Fig. 64). with a belt tension gauge on vehicles equipped with
an automatic belt tensioner. Refer to Automatic Belt
(2) Install new belt. Refer to the end of this group Tensioner in this group.
for Drive Belt Tension specifications.
(3) After power steering pump bracket and idler
pulley has been tightened into position, recheck belt REMOVAL
tension. Adjust if necessary. (1) Attach a socket/wrench to pulley mounting bolt
of automatic belt tensioner (Fig. 65).
Fig. 63 Power Steering Pump Bracket and Idler Pulley

Fig. 65 Belt Tensioner—5.2L Engine Fig. 66 Belt Routing—5.2L Engine

(2) Rotate tensioner assembly clockwise (as viewed has been used 15 minutes or less. If this specifica-
from front) until tension has been relieved from belt. tion cannot be met, check for:
(3) Remove belt from idler pulley first. The wrong belt being installed (incorrect length/
(4) Remove belt from vehicle. width)
Worn bearings on an engine accessory (A/C com-
INSTALLATION pressor, power steering pump, water pump, idler
pulley or generator)
CAUTION: When installing serpentine accessory A pulley on an engine accessory being loose
drive belt, the belt must be routed correctly. If not, Misalignment of an engine accessory
engine may overheat due to water pump rotating in Belt incorrectly routed.
wrong direction. Refer to (Fig. 66) for correct engine A used belt should be replaced if tensioner index-
belt routing. The correct belt with correct length ing arrow has moved to point-A (Fig. 67). Tensioner
must be used. travel stops at point-A.
(1) Position drive belt over all pulleys except idler
pulley. This pulley is located between generator and REMOVAL
A/C compressor. (1) Remove accessory drive belt. Refer to Belt
(2) Attach a socket/wrench to pulley mounting bolt Removal/Installation in this group.
of automatic tensioner (Fig. 65). (2) Disconnect wiring and secondary cable from
(3) Rotate socket/wrench clockwise. Place belt over ignition coil.
idler pulley. Let tensioner rotate back into place. (3) Remove ignition coil from coil mounting
Remove wrench. Be sure belt is properly seated on bracket (two bolts). Do not remove coil mounting
all pulleys. bracket from cylinder head.
(4) Check belt indexing marks. Refer to Automatic (4) Remove tensioner assembly from mounting
Belt Tensioner. bracket (one nut) (Fig. 67).
AUTOMATIC BELT TENSIONER WARNING: BECAUSE OF HIGH SPRING PRES-

SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
NOTE: On 5.2 engines, the tensioner is equipped MATIC TENSIONER. UNIT IS SERVICED AS AN
with an indexing arrow (Fig. 67) on back of ten- ASSEMBLY (EXCEPT FOR PULLEY).
sioner and an indexing mark on tensioner housing.
If a new belt is being installed, arrow must be (5) Remove pulley bolt. Remove pulley from ten-
within approximately 3 mm (1/8 in.) of indexing sioner.
mark (point B-) (Fig. 67). Belt is considered new if it
center of fan shroud. Fan belt removal is not neces-
sary as the water pump studs will hold the pump
pulley in position. Do not remove fan assembly from
vehicle at this time.
Fig. 68 Fan Mounting Nuts—4.0L 6-Cyl. Engine

Fig. 67 Belt Tensioner/Pulley Assembly—5.2L (2) Remove the two fan shroud-to-upper radiator
Engine crossmember mounting nuts (Fig. 69).
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N·m (45 ft. lbs.) torque.
(2) Install tensioner assembly to mounting
bracket. An indexing tab is located on back of ten-
sioner. Align this tab to slot in mounting bracket.
Tighten nut to 67 N·m (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
(4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 N·m
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
N·m (50 in. lbs.) torque.
CAUTION: To prevent damage to coil case, coil

mounting bolts must be torqued.
(5) Install drive belt. Refer to Belt Removal/Instal-

lation in this group.
(6) Check belt indexing marks (Fig. 67).
COOLING SYSTEM FAN 4.0L ENGINE

Fig. 69 Fan Shroud Mounting Nuts
REMOVAL
(1) Remove the four fan hub-to-water pump pulley (3) Remove fan, viscous fan drive and fan shroud
mounting nuts (Fig. 68). Carefully remove the fan as an assembly from the vehicle.
assembly from the water pump pulley and position to
(4) Remove the four fan blade-to-viscous fan drive
mounting bolts. Remove viscous fan drive from fan
blades.
(5) After removing fan blade/fan drive assembly do
not place the thermal viscous fan drive in the hori-
zontal position. If stored horizontally, the silicone
fluid in the viscous fan drive could drain into the
bearing assembly and contaminate the lubricant.
INSTALLATION
(1) Assemble fan blades to viscous fan drive.
Tighten mounting bolts to 24 N·m (18 ft. lbs.) torque.
(2) Position fan, viscous fan drive and fan shroud
to the engine as one assembly.
(3) Position fan shroud to radiator. Be sure the
alignment tabs at the lower part of shroud are placed
into the slots near lower part of radiator.
Be sure the upper and lower portions of the fan
shroud are firmly connected. All air must flow
(4) Position mounting flange of fan/viscous fan
drive assembly onto water pump pulley. Install four
nuts and tighten to 24 N·m (18 ft. lbs.) torque. Fig. 70 Fan Blade/Viscous Fan Drive—5.2L V-8
(5) Install two fan shroud mounting nuts. Engine
Be sure of at least 25 mm (1.0 inches) between tips
CAUTION: Do not remove water pump pulley-to-
of fan blades and fan shroud.
water pump bolts. This pulley is under spring ten-
sion.
COOLING SYSTEM FAN 5.2L ENGINE
(8) Remove four bolts securing fan blade assembly
REMOVAL
to viscous fan drive.
(2) The thermal viscous fan drive/fan blade assem- INSTALLATION
bly is attached (threaded) to water pump hub shaft (1) Install fan blade assembly to viscous fan drive.
(Fig. 70). Remove fan blade/viscous fan drive assem- Tighten bolts to 23 N·m (17 ft. lbs.) torque.
bly from water pump by turning mounting nut coun- (2) Position fan shroud and fan blade/viscous fan
terclockwise as viewed from front. Threads on drive assembly to vehicle as a complete unit.
viscous fan drive are RIGHT HAND. A Snap-On 36 (3) Position fan shroud to radiator. Be sure the
MM Fan Wrench (number SP346 from Snap-On alignment tabs at the lower part of shroud are placed
Cummins Diesel Tool Set number 2017DSP) can be into the slots near lower part of radiator. Install and
used. Place a bar or screwdriver between water tighten the two fan shroud-to-upper crossmember
pump pulley bolts to prevent pulley from rotating. mounting nuts.
(3) Do not attempt to remove fan/viscous fan drive Be sure of at least 25 mm (1.0 inches) between tips
assembly from vehicle at this time. of fan blades and fan shroud.
(4) Do not unbolt fan blade assembly from viscous (4) Install fan blade/viscous fan drive assembly to
fan drive at this time. water pump shaft.
(5) Remove two fan shroud-to-upper crossmember (5) Connect negative battery cable.
nuts (Fig. 69).
(6) Remove fan shroud and fan blade/viscous fan VISCOUS FAN DRIVE
drive assembly as a complete unit from vehicle.
(7) After removing fan blade/viscous fan drive REMOVAL/INSTALLATION
assembly, do not place viscous fan drive in horizon- Refer to Cooling System Fan removal and installa-
tal position. If stored horizontally, silicone fluid in tion procedures of the viscous fan drive unit proce-
the viscous fan drive could drain into its bearing dures.
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a NEW viscous fan drive, bring the
engine speed up to approximately 2000 rpm and hold
for approximately two minutes. This will ensure • Impeller rubs either the pump body or timing
proper fluid distribution within the drive. chain case/cover
CLEANING AND INSPECTION SPECIFICATIONS

RADIATOR CAP INFORMATION
The following specifications are published from the
INSPECTION latest information available at the time of publica-
Visually inspect the pressure valve gasket on the tion. If anything differs between the specifica-
cap. Replace cap if the gasket is swollen, torn or tions found on the Vehicle Emission Control
worn. Inspect the area around radiator filler neck for Information (VECI) label and the following
white deposits that indicate a leaking cap. specifications, use specifications on VECI label.
The VECI label is located in the engine compart-
RADIATOR ment. Refer to Group 25, Emission System for more
information on the VECI label.
CLEANING
The radiator and air conditioning fins should be COOLING SYSTEM CAPACITIES
cleaned when an accumulation of bugs, leaves etc.
has occurred. Clean radiator fins are necessary for
good heat transfer. With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con-
denser of debris.
FAN BLADE INSPECTION

The fan blades cannot be repaired. If the fan is
damaged, it must be replaced. Inspect the fan blades
as follows:
Lay fan blade assembly on a flat surface with lead-
ing edge facing down. With tip of blade touching flat
surface, replace fan if clearance between opposite
blade and surface is greater than 2.0 mm (.090 inch).
Rocking motion of opposite blades should not exceed
2.0 mm (.090 inch). Test all blades in this manner.
WARNING: IF FAN IS NOT WITHIN SPECIFICA-

TIONS, DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN.
Inspect fan assembly for cracks, bends, loose rivets

or broken welds. Replace fan if any damage is found.
CAUTION: If the fan blade assembly is replaced

because of mechanical damage, the water pump
and viscous fan drive should also be inspected.
These components could have been damaged due
to excessive vibration.
WATER PUMP INSPECTION

Replace water pump assembly if it has any of the
following conditions:
• The body is cracked or damaged
• Water leaks from shaft seal. This is evident by
traces of coolant below vent hole
• Loose or rough turning bearing. Also inspect vis-
cous fan drive
SPECIFICATIONS (Continued)
DRIVE BELT TENSION SPECIAL TOOLS
COOLING
Pliers 6094
TORQUE
Pressure Tester 7700–A

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ZJ COOLING SYSTEM 7-1

GENERAL INFORMATION VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 22

GENERAL INFORMATION ing in wrong direction. Refer to the appropriate

COOLING SYSTEM COMPONENTS

Fig. 2 Engine Cooling System—5.2L Engine—Typical

ACCESSORY DRIVE BELT TENSION

Fig. 5 Block Heater—4.0L 6-Cyl. Engine

Fig. 4 Coolant Reserve/Overflow Tank—Typical

ENGINE BLOCK HEATER

Fig. 7 Radiator Pressure Cap—Typical

WATER PUMP COOLING SYSTEM HOSES

VISCOUS FAN DRIVE

NOTE: It is normal for fan noise to be louder (roar-

• The underhood temperature is above the engage-

DIAGNOSIS AND TESTING

Fig. 14 Check Engine Lamp Location

WARNING: DO NOT LOOSEN THE RADIATOR

(1) Drain sufficient coolant from the radiator to

NOTE: Remove the pump from the engine before

Fig. 17 Serpentine Belt Wear Patterns

Fig. 19 Pressurizing System—Typical

(6) Start the engine and operate at 2400 rpm.

RADIATOR CAP-TO-FILLER NECK SEAL—

WARNING: THE WARNING WORDS —DO NOT

Fig. 21 Drain Plug—4.0L 6-Cylinder Engine COOLING SYSTEM CLEANING/REVERSE FLUSHING

REVERSE FLUSHING ENGINE

CAUTION: Be sure instructions on the container

REMOVAL AND INSTALLATION

WATER PUMP 4.0L ENGINE

The water pump impeller is pressed on the rear of

WARNING: DO NOT REMOVE THE BLOCK DRAIN

Fig. 29 Hose Clamp Tool—Typical

Fig. 28 Power Steering Pump Attachment

CAUTION: When installing the serpentine engine

(8) Adjust accessory drive belt, refer to Accessory

WATER PUMP 5.2L ENGINE

Fig. 33 Fan Shroud Nuts

Fig. 36 Water Pump Bolts—5.2L Engine—Typical

CAUTION: A number or letter is stamped into the

(2) Remove radiator upper hose and heater hose at

THERMOSTAT 4.0L ENGINE

WARNING: DO NOT LOOSEN THE RADIATOR

Fig. 39 Thermostat Recess—4.0L Engine

CAUTION: Tightening the thermostat housing

(3) Tighten the housing bolts to 22 N·m (16 ft. lbs.)

Fig. 42 Thermostat—5.2L Engine

Fig. 41 Automatic Belt Tensioner—5.2L Engine

Fig. 45 Hose Clamp Tool—Typical

WARNING: DO NOT REMOVE THE CYLINDER

Fig. 47 Air Seals—Typical

Fig. 49 Fan Blade and Viscous Fan Drive—5.2L V-8

CAUTION: Note the location of all rubber air seals

WITH AIR CONDITIONING

WARNING: THE A/C SYSTEM IS UNDER PRES-

(1) Disconnect negative battery cable from battery.

CAUTION: When installing serpentine accessory

Fig. 57 Belt Tensioner Assembly—5.2L Engine

Fig. 61 Block Heater—4.0L Engine

Fig. 59 Drain Plug—4.0L 6-Cylinder Engine

Fig. 62 Block Heater—5.2L Engine