Professional Documents
Culture Documents
7 - 1
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or by the particular vehicle nameplate. A chart showing a breakdown of alphabetical designations is included in the Introduction section at the beginning of this manual.
COOLING SYSTEM
The cooling system regulates engine operating temperature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also maintains normal operating temperature and prevents overheating. The cooling system also provides a means of heating the passenger compartment and cooling the automatic 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 cooling package is available on most models. This package will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures.
7 - 2
COOLING SYSTEM
Coolant reserve/overflow system Transmission oil cooler (if equipped with an automatic transmission) Coolant Water pump Hoses and hose clamps
7 - 3
for eventual display to the service technician. If the problem is repaired or ceases to exist, the PCM cancels the DTC after 51 engine starts. 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. A DTC indicates that the PCM has recognized an abnormal signal in a circuit or the system. A DTC may indicate the result of a failure, but never identify the failed component directly. It is possible that a DTC for a monitored circuit may not be entered into memory even though a malfunction has occurred. Refer to On-Board Diagnostics (OBD) in Group 14, Fuel Systems for additional information.
ACCESSING DIAGNOSTIC TROUBLE CODES A stored Diagnostic Trouble Code (DTC) can be displayed by cycling the ignition key On-Off-On-Off-On within three seconds and observing the malfunction indicator lamp. This lamp is displayed on the instrument panel as the CHECK ENGINE lamp (Fig. 3). They can also be displayed through the use of the Diagnostic Readout Box (DRB) scan tool. The DRB connects to the data link connector in the engine compartment (Fig. 4). For operation of the DRB, refer to the appropriate Powertrain Diagnostic Procedures service manual.
EXAMPLES: If the lamp (Fig. 3) flashes 1 time, pauses and flashes 2 more times, a flashing Diagnostic Trouble Code (DTC) number 12 is indicated. If this code is observed, it is indicating that the battery has been disconnected within the last 50 key-on cycles. It could also indicate that battery voltage has been disconnected to the PCM. In either case, other DTCs may have been erased. If the lamp flashes 1 time, pauses and flashes 7 more times, a flashing Diagnostic Trouble Code (DTC) number 17 is indicated. If the lamp flashes 3 times, pauses and flashes 5 more times, a flashing Diagnostic Trouble Code (DTC) number 35 is indicated.
7 - 4
ERASING TROUBLE CODES After the problem has been repaired, use the DRB scan tool to erase a DTC. Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool.
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause:
7 - 5
7 - 6
7 - 7
7 - 8
7 - 9
7 - 10
7 - 11
7 - 12
Automatic Transmission Oil Coolers . . . . . . . Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Reserve/Overflow System . . . . . . . . Cooling System Cleaning/Reverse Flushing . Cooling System Fan2.5L 4-Cylinder Engine Cooling System Fan3.9L/5.2L Engine . . . . Cooling System Hoses . . . . . . . . . . . . . . . . Draining Cooling System . . . . . . . . . . . . . . . Pressure Testing Radiator Caps . . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
32 23 27 25 33 36 32 24 28
WATER PUMPSREMOVAL/INSTALLATION
The water pump on all models can be removed without discharging the air conditioning system (if equipped).
2.5L 4-CYLINDER ENGINE The water pump used on 2.5L engines consists of a die-cast aluminum body and housing, and a stamped steel impeller. A gasket is used to seal between the pump body and housing. The water pump assembly bolts directly to the engine cylinder block. A rubber o-ring provides the seal between water pump and cylinder block (Fig. 1).
REMOVAL (1) Drain cooling system. (2) Remove accessory drive belt. (3) Remove generator. Refer to Group 8B, Battery/ Starter/Generator Service. CAUTION: If vehicle is equipped with air conditioning, the solid mount accessory drive bracket must be removed according to the following procedure:
7 - 13
7 - 14
CAUTION: The solid mount accessory bracket fasteners must be tightened in following sequence. (e) Tighten bolt 1 (Fig. 2) to 3 Nm (30 in. lbs.) torque. (f) Tighten nut 2 and bolt 3 (Fig. 2) to 54 Nm (40 ft. lbs.) torque. (g) Tighten bolts 1, 4 and 5 (Fig. 2) to 54 Nm (40 ft. lbs.) torque. (h) Tighten bolts 6 and 7 (Fig. 2) to 54 Nm (40 ft. lbs.) torque. (i) Install air conditioning compressor. Tighten mounting bolts to 54 Nm (40 ft. lbs.) torque. (3) Install generator. Refer to Group 8B, Battery/ Starter/ Generator Service. (4) Install accessory drive belts. Refer to the Engine Accessory Drive Belt section of this group for installation procedure and belt tension specifications. (5) Fill cooling system with coolant. Refer to the Refilling Cooling System section in this group. (6) Start and warm the engine. Check for leaks.
3.9L/5.2L ENGINE The water pump on 3.9L and 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 have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal Viscous Fan Drive. Refer to Viscous Fan Drive in this group.
7 - 15
7 - 16
(10) Remove four water pump pulley-to-water pump hub bolts (Fig. 6) and remove pulley from vehicle. (11) Remove lower radiator hose clamp and remove lower hose at water pump. (12) Remove heater hose clamp (Fig. 3) and heater hose from heater hose coolant return tube. (13) Loosen heater hose coolant return tube mounting bolt (Fig. 8) and remove tube from water pump. Discard the old tube o-ring.
7 - 17
7 - 18
7 - 19
wrong direction. Refer to (Fig. 17) for correct belt routing. The correct belt with correct length must be used.
THERMOSTAT
GENERAL INFORMATIONALL ENGINES On 2.5L 4-cylinder engines, the thermostat is located inside the water box at front of engine on radiator side (Fig. 18). This thermostat does not have an air bleed notch. On 3.9L and 5.2L engines, the thermostat is located beneath the thermostat housing at front of intake manifold (Fig. 19). This thermostat has an air bleed notch. All thermostats (2.5L, 3.9L and 5.2L engines) are of the wax-pellet-driven, reverse-poppet-choke-type. The wax pellet is located in a sealed container at spring end of thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force valve to open. Coolant leakage into pellet container will cause thermostat to fail in open position. Do not attempt to free a sticking thermostat with a prying device. The thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to radiator. On all engines (2.5L, 3.9L and 5.2L), thermostat is closed below 88C (192F). When cool-
7 - 20
7 - 21
If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. Factory installed thermostat housings on 3.9L/5.2L engines are installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. (1) Disconnect negative battery cable at battery. (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 manifold) located near rear of generator (Fig. 20).
INSTALLATION2.5L ENGINE If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. (1) Dip replacement gasket in water and position on water box (Fig. 18). (2) Assemble the thermostat and thermostat housing as shown in (Fig. 18). Be sure the thermostat is centered into thermostat housing and that spring side is installed towards cylinder head.
CAUTION: Tightening housing unevenly or without thermostat centered, may result in a cracked housing. (3) Install housing stud/bolts. Tighten housing stud/bolts to 23 Nm (200 in. lbs.) torque. (4) Install ignition coil/coil mounting bracket assembly. (5) Install upper radiator hose to thermostat housing. (6) Connect negative battery cable to battery. (7) Fill cooling system. Refer to Refilling Cooling System in this group.
REMOVAL3.9L/5.2L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
7 - 22
INSTALLATION3.9L/5.2L ENGINE (1) Clean mating areas of intake manifold and thermostat housing. (2) Install thermostat (spring side down) into recessed machined groove on intake manifold (Fig. 22). (3) Install gasket on intake manifold and over thermostat (Fig. 22). (4) Position thermostat housing to intake manifold. Note the word FRONT stamped on housing (Fig. 23). For adequate clearance, this must be placed towards
7 - 23
coolant carries heat to radiator and heater core. Here it is transferred to ambient air passing through radiator and heater core fins. The coolant also removes heat from automatic transmission fluid in vehicles equipped with an automatic transmission.
COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100% Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149C (300F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethyleneglycol freezes at -22C (-8F). 50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37C (-35F). The antifreeze concentration must always be a minimum of 44 percent, yearround in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7C (-90F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.
COOLANT SELECTION-ADDITIVES Coolant should be maintained at the specified level with a mixture of ethylene glycol-based antifreeze and low mineral content water. Only use an antifreeze containing ALUGARD 340-2 .
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
COOLANT
The cooling system is designed around the coolant. Coolant flows through the engine water jackets absorbing heat produced during engine operation. The
COOLANT SERVICE It is recommended that the cooling system be drained and flushed at 84,000 kilometers (52,500
7 - 24
miles), or 3 years, whichever occurs first. Then every two years, or 48,000 kilometers (30,000 miles), whichever occurs first.
COOLANT LEVEL CHECK-ROUTINE Do not remove radiator cap for routine coolant level inspections. The coolant level can be checked at coolant reserve/overflow tank. The coolant reserve/overflow system provides a quick visual method for determining coolant level without removing radiator pressure cap. With engine idling and at normal operating temperature, observe coolant level in reserve/overflow tank. The coolant level should be between ADD and FULL marks. ADDING ADDITIONAL COOLANT-ROUTINE Do not remove radiator cap to add coolant to system. When adding coolant to maintain correct level, do so at coolant reserve/overflow tank. Use a 50/50 mixture of ethylene-glycol antifreeze containing Alugard 340-2 and low mineral content water. Remove radiator cap only for testing or when refilling system after service. Removing cap unnecessarily can cause loss of coolant and allow air to enter system, which produces corrosion. COOLANT LEVEL CHECK-SERVICE The cooling system is closed and designed to maintain coolant level to top of radiator.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK WITH ENGINE RUNNING OR WHILE ENGINE IS HOT AND COOLING SYSTEM IS UNDER PRESSURE. When vehicle servicing requires a coolant level check in radiator, drain several ounces of coolant from radiator drain cock. Do this while observing coolant reserve/overflow system tank. The coolant level in reserve/overflow tank should drop slightly. If not, inspect for a leak between radiator and coolant reserve/overflow system connection. Remove radiator cap. The coolant level should be to top of radiator. If not, and if coolant level in reserve/overflow tank is at ADD mark, check for: An air leak in coolant reserve/overflow tank or its hose An air leak in radiator filler neck Leak in pressure cap seal to radiator filler neck
DEAERATION As the engine operates, any air trapped in cooling system gathers under the radiator cap. The next time the engine is operated, thermal expansion of coolant will push any trapped air past radiator cap into the coolant reserve/overflow tank. Here it escapes to the atmosphere into the tank. When the engine cools down the coolant, it will be drawn from the reserve/ overflow tank into the radiator to replace any removed air.
LOW COOLANT LEVEL-AERATION If the coolant level in radiator drops below top of radiator core tubes, air will enter cooling system. On 2.5L engines, air can gather in the water box containing the thermostat. Low coolant level can cause thermostat pellet to be suspended in air instead of coolant. This will cause thermostat to open later, which in turn causes higher coolant temperature. Air trapped in cooling system
7 - 25
Allow radiator to fill with water. When radiator is filled, apply air in short blasts. Allow radiator to refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. Have radiator cleaned more extensively by a radiator repair shop.
REVERSE FLUSHING ENGINE Drain cooling system. Remove thermostat housing and thermostat. Install thermostat housing. Disconnect radiator upper hose from radiator and attach flushing gun to hose. Disconnect radiator lower hose from water pump and attach a lead-away hose to water pump inlet fitting.
CAUTION: On vehicles equipped with a heater water control valve, be sure heater control valve is closed (heat off). This will prevent coolant flow with scale and other deposits from entering heater core. Connect water supply hose and air supply hose to flushing gun. Allow engine to fill with water. When engine is filled, apply air in short blasts, allowing system to fill between air blasts. Continue until clean water flows through the lead away hose. Remove lead away hose, flushing gun, water supply hose and air supply hose. Remove thermostat housing and install thermostat. Install thermostat housing with a replacement gasket. Refer to Thermostat Replacement. Connect radiator hoses. Refill cooling system with correct antifreeze/water mixture. Refer to Refilling the Cooling System.
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 flushing operation.
CAUTION: Follow manufacturers instructions when using these products. Aluminum Hydroxide Deposition is a type of corrosion encountered in cooling system of engines that are of an aluminum composition. This would be on a 2.5L engine with aluminum cylinder head. It appears as dark grey when wet, but, when dry it is white. This type of corrosion can usually be removed with a commercially available two part cleaner (oxcilac acid and neutralizer). Follow manufacturers directions for use. However, it is recommended that engine be operated one extra hour if acid is in coolant.
7 - 26
light (black light). Pour one ounce of additive into cooling system. Place heater control unit in HEAT position. Start and operate engine until radiator upper hose is warm to touch. Aim the commercially available black light tool at components to be checked. If leaks are present, black light will cause additive to glow a bright green color. The black light can be used in conjunction with a pressure tester to determine if any external leaks exist (Fig. 26).
INTERNAL LEAKAGE INSPECTION Remove engine oil pan drain plug and drain a small amount of engine oil. If coolant is present in the pan, it will drain first because it is heavier than oil. An alternative method is to operate engine for a short period to churn the oil. After this is done, remove engine dipstick and inspect for water globules. Also inspect transmission dipstick for water globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER TOOL INSTALLED ON RADIATOR, DO NOT ALLOW PRESSURE TO EXCEED 110 KPA (20 PSI). PRESSURE WILL BUILD UP QUICKLY IF A COMBUSTION LEAK IS PRESENT. TO RELEASE PRESSURE, ROCK TESTER FROM SIDE TO SIDE. WHEN REMOVING TESTER, DO NOT TURN TESTER MORE THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
7 - 27
vides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides 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. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator.
COMBUSTION LEAKAGE TESTWITHOUT PRESSURE TESTER DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. Drain sufficient coolant to allow thermostat removal. Refer to Thermostat Replacement. Disconnect water pump drive belt. Add coolant to radiator to bring level to within 6.3 mm (1/4 in) of top of thermostat housing. CAUTION: Avoid overheating. Do not operate engine for an excessive period of time. Open draincock immediately after test to eliminate boil over. Start engine and accelerate rapidly three times, to approximately 3000 rpm while observing coolant. If internal engine combustion gases are leaking into cooling system, bubbles will appear in coolant. If bubbles do not appear, internal combustion gas leakage is not present.
TANK REMOVAL (1) Remove overflow hose at reserve/overflow tank. (2) Unsnap the coolant reserve/overflow tank from fan shroud. Lift straight up. The fan shroud is equipped with T-shaped slots to attach the tank. TANK INSTALLATION (1) Snap tank into fan shroud. (2) Install overflow hose to tank.
7 - 28
spring-loaded pressure relief valve that opens when system pressure reaches release range of 97-124 kPa (14-18 psi).
RADIATOR CAP-TO-FILLER NECK SEAL PRESSURE RELIEF CHECK The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at a minimum of 55 kPa (8 psi).
WARNING: THE WARNING WORDS DO NOT OPEN HOT ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove radiator cap at any time except for the following purposes: (1) Check and adjust antifreeze freeze point. (2) Refill system with new antifreeze. (3) Conducting service procedures.
7 - 29
INSPECTION Hold cap at eye level, right side up. The vent valve (Fig. 29) at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator.
RADIATOR
The radiators used in these models are of the down-flow type (vertical tubes) and have plastic tanks. The radiator supplies sufficient heat transfer to cool engine. CAUTION: Although plastic radiator tanks are stronger than brass, they are more susceptible to damage from impact or excessive hose clamp torque. In the event of damage to a plastic radiator tank, replacement tanks and o-ring seals (Fig. 31) are available through the parts department. Tank repair should be performed by qualified personnel using proper equipment.
RADIATOR REMOVAL2.5L 4-CYLINDER ENGINE (1) Disconnect negative battery cable from battery.
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. (2) Drain cooling system. Refer to Draining Cooling System. 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. 32). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
RADIATOR COOLANT FLOW CHECK Use the following procedure to determine if coolant is flowing through cooling system. (1) Idle engine until operating temperature is reached. If upper radiator hose is warm to the touch, thermostat is opening and coolant is flowing to radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO FIRST STOP. ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/ OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK.
7 - 30
CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 33). If replacement is necessary, use only an original equipment clamp with matching number or letter.
7 - 31
RADIATOR INSTALLATION3.9L/5.2L ENGINE The radiator has two alignment pins on bottom of lower tank. These fit into alignment holes in radiator lower support. (1) Lower radiator into engine compartment. Position alignment pins into alignment holes in radiator lower support. (2) Install two upper radiator bolts. (3) Install transmission cooler lines (if equipped). (4) Install both radiator hoses and hose clamps (Fig. 32). (5) Install fan shroud to radiator (two clips at toptwo bolts at bottom). (6) Install coolant reserve/overflow tank. Snaps into position. (7) Connect throttle cable to fan shroud. Snaps in. (8) Connect negative battery cable to battery. (9) Fill cooling system. Refer to Refilling Cooling System section in this group. (10) Start and warm the engine. Check for leaks.
7 - 32
(2) Using a pair of needle nose pliers, compress draincock body and pull straight out of radiator (Fig. 36).
RADIATOR CLEANING The radiator and air conditioning fins should be 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 condenser of debris.
7 - 33
AUXILIARY OIL-TO-AIR COOLER Oil-to-air transmission coolers are mounted ahead of radiator. They operate in conjunction with main cooler located in radiator lower tank (Fig. 41). The transmission oil is routed through main cooler in radiator lower tank first. It is then routed through auxiliary cooler before returning to transmission.
7 - 34
TESTING ELECTRICAL COOLING FAN2.5L ENGINE The powertrain control module (PCM) will enter a diagnostic trouble code (DTC) number 35 in memory if it detects a problem in the electric cooling fan relay or circuit. This will be read as a flashing signal at the instrument panel mounted malfunction indicator lamp (displayed on the instrument panel as the CHECK ENGINE lampfigure 44). Refer to OnBoard Diagnostics in Group 14, Fuel Systems for more information on accessing a DTC. The DTC can also be accessed through the DRB scan tool. Refer to the appropriate Powertrain Diagnostic Procedures manual for diagnostic information and operation of the DRB scan tool. The cooling fan motor can be tested by applying 12 volts + to the fan motor connector. Disconnect fan motor connector from harness connector. Using 14gage wire and ensuring correct polarity (Fig. 42), connect battery voltage (12 volts) to fan motor connector. If fan operates normally, fan motor is functioning properly. If fan does not operate, replace fan. If motor has signs of being overheated such as melted wire insulation or charred contacts, the system charging voltage may be too high. Refer to Group 8A, Battery/ Starting/Charging System Diagnostics. RADIATOR FAN MOTOR INOPERATIVE Equipment Required: DRB Scan Tool Volt/Ohm meter Wiring Diagrams section of this manual Test Procedure
7 - 35
7 - 36
If battery voltage is present, replace fan relay If voltage reading is 0, repair open or short in circuit-C27 (10) Turn ignition switch off. Connect 60-way connector to PCM. Test system operation.
FAN REMOVAL2.5L ENGINE The fan blade is not repairable. If the fan is bent, warped, cracked or damaged in any way, it must be replaced only with recommended replacement fan. This is done to be sure of adequate strength, performance and safety. (1) Disconnect negative battery cable from battery. (2) Disconnect fan motor wire connector. (3) Remove the two fan shroud mounting clips connecting the upper part of fan shroud to the radiator (Fig. 34). (4) Remove fan, shroud and motor from radiator as an assembly. (5) Support fan motor and shaft on a bench. Do not allow fan blades to contact bench. Remove fan retaining clip (Fig. 47).
REMOVAL (1) Disconnect negative battery cable from battery. (2) Remove throttle cable at top of fan shroud. (3) Unsnap coolant reserve/overflow tank from fan shroud and lay aside. The tank is held to shroud with T-shaped slots. Do not disconnect hose or drain coolant from tank. (4) The thermal viscous fan drive/fan blade assembly is attached (threaded) to water pump hub shaft (Fig. 48). Remove fan blade/viscous fan drive assembly from water 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. 48) to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
7 - 37
INSPECTION The fan blades cannot be repaired. If fan is damaged, it must be replaced. Inspect fan as follows: (1) Remove fan blade and viscous fan drive as an assembly from the engine. Refer to preceding Removal procedure. (2) Remove fan blade assembly from viscous fan drive unit (four bolts). (3) Lay fan on a flat surface with leading 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: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS. (4) Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration.
The thermal viscous fan drive (Figs. 48 or 49) 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 the front face of the viscous fan drive unit (a typical viscous unit is shown in figure 49). This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed.
INSTALLATION (1) Install fan blade assembly to viscous fan drive. Tighten bolts (Fig. 48) to 23 Nm (17 ft. lbs.) torque. (2) Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. (3) Install fan shroud. (4) Install fan blade/viscous fan drive assembly to water pump shaft (Fig. 48). (5) Install coolant reserve/overflow tank to fan shroud. Snaps into position. (6) Install throttle cable to fan shroud. (7) Connect negative battery cable.
7 - 38
CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could 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 It is normal for fan noise to be louder (roaring) when: The underhood temperature is above the engagement 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. 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. TESTING If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature. WARNING: BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING. (1) Drill a 3.18-mm (1/8-in) diameter hole in the top center of the fan shroud. (2) Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18-to-
VISCOUS FAN DRIVE REMOVAL/ INSTALLATION Refer to the previous section on Cooling System Fan3.9L/5.2L Engine for removal and installation procedures of the viscous drive unit. 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 proper fluid distribution within the drive.
7 - 39
BELT DIAGNOSIS
V-BELT DIAGNOSIS2.5L 4-CYLINDER ENGINE ONLY Refer to the V-Belt diagnosis chart. SERPENTINE DRIVE BELT DIAGNOSISALL ENGINES When diagnosing serpentine drive belts, small cracks that run across ribbed surface of belt from rib to rib (Fig. 1), are considered normal. These are not a reason to replace belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 1). Also replace belt if it has excessive wear, frayed cords or severe glazing. Refer to the Serpentine Drive Belt Diagnosis charts for further belt diagnosis. Also refer to Automatic Belt Tensioner3.9L/5.2L Engine, proceeding in this group.
7 - 40
7 - 41
7 - 42
7 - 43
2.5L 4-CYLINDER ENGINE ONLY There are different gauges for checking Poly-V serpentine (multi-ribbed) belts and conventional V-belts. Use correct gauge when checking belt tension. Place gauge in middle of section of belt being used to check tension. The gauge can only contact belt or a false reading may result. The edge of belt must be against stops on belt tension gauge. Release gauge handle rapidly for correct reading. Refer to the Belt Tension chart in the Specifications section at end of this group for tension specifications. A belt is considered used after 15 minutes of use. 3.9L/5.2L ENGINE ONLY It is not necessary to adjust belt tension on 3.9L (V-6) or 5.2L (V-8) engine. The engine is equipped with an automatic belt tensioner (Fig. 5). The tensioner maintains correct belt tension at all times. For other tensioner information and removal/installation procedures, refer to Automatic Belt Tensioner3.9L/ 5.2L Engine proceeding in this group. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 3.9L/5.2L engines.
BELT TENSION
ALL ENGINES Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of
BELT REMOVAL/INSTALLATION
GENERATOR BELT2.5L ENGINE
REMOVAL (1) Disconnect negative battery cable from battery. (2) Loosen generator mounting bolt (Fig. 6).
7 - 44
AIR CONDITIONING BELT2.5L ENGINE (1) Disconnect negative battery cable from battery. (2) Loosen idler bracket pivot screw and locking screws (Fig. 7) to remove or replace air conditioning belt. The lower locking screw must be removed to remove/install belt.
POWER STEERING BELT2.5L ENGINE (1) Disconnect negative battery cable from battery. (2) Loosen locking screw (Fig. 8). (3) Loosen pivot bolt (Fig. 8). (4) Loosen pivot nut at rear of power steering pump. (5) Remove or replace power steering belt. (6) The power steering pump adjusting bracket is equipped with a 1/2 inch square hole. Insert a 1/2 inch drive breaker bar into opening and adjust belt
7 - 45
7 - 46
INSTALLATION (1) Install pulley and pulley bolt to tensioner. Tighten bolt to 61 Nm (45 ft. lbs.). (2) Install tensioner assembly to mounting bracket. An indexing tab is located on back of tensioner. Align this tab to slot in mounting bracket. Tighten nut to 67 Nm (50 ft. lbs.). (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 Nm (100 in. lbs.) torque. If coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 Nm (50 in. lbs.) torque.
CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued. (5) Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). 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. 4) for correct 3.9L/ 5.2L engine belt routing. The correct belt with correct length must be used (6) Attach a socket/wrench to pulley mounting bolt of automatic tensioner (Fig. 9). (7) 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. (8) Check belt indexing marks.
REMOVAL (1) Attach a socket/wrench to mounting bolt of automatic tensioner pulley bolt (Fig. 9). (2) Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. (3) Remove belt from idler pulley first. (4) Remove belt from other pulleys. (5) Disconnect wiring and secondary cable from ignition coil.
7 - 47
REMOVAL (1) Disconnect negative battery cable from battery. (2) Drain coolant from radiator and cylinder block. Refer to Draining Cooling System in this group. (3) Remove power cord from block heater (Fig. 1). (4) Loosen screw at center of block heater. Remove heater assembly. 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 Nm (17 in. lbs.) torque. (4) Fill cooling system with recommended coolant. Refer to Filling Cooling System section in this group. (5) Start and warm the engine. Check for leaks.
7 - 48
GENERAL INFORMATION
The following specifications are published from the latest information available at the time of publication. If anything differs between the specifications found on the Vehicle Emission Control Information (VECI) label and the following specifications, use specifications on VECI label. The VECI label is located in the engine compartment. Refer to Group 25, Emission System for more information on the VECI label.
TORQUE
COOLANT CAPACITIES