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water pump operation.
1. During wet weather, moisture (snow, ice or rain condensation) on the radiator will evaporate when the thermostat opens. This opening allows heated water into the radiator. When the moisture contacts the hot radiator, steam may be emitted. This usually occurs in cold weather with no fan or airflow to blow it away.
1. Coolant color is not necessarily an indication of adequate corrosion or temperature protection. Do not rely on coolant color for determining condition of coolant.
1. Level changes are to be expected as coolant volume fluctuates with engine temperature. If the level in the tank was between the FULL and ADD marks at normal operating temperature, the level should return to within that range after operation at elevated temperatures.
DR COOLING (Continued) STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT LEVEL CHECK
level
NOTE: Do not remove radiator cap for routine cool- ant level can be checked at coolant recovery bottle or the coolant degas bottle.
inspections. The coolant
WARNING: DO NOT REMOVE OR LOOSEN THE RADIATOR CAP WITH THE COOLING SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT OR HIGH PRESSURE STEAM CAN OCCUR.
The 5.9L, 5.9L Diesel, and 8.0L engine coolant reserve / overflow system provides a quick method for determining the coolant level without removing the radiator pressure cap. With the engine at normal operating temperature and idling, observe the level of the coolant on the external level indicator on the side of the coolant reserve / overflow bottle. The cool- ant level should be between the MIN and MAX marks. If the coolant is below the MIN mark, add a 50/50 mixture of antifreeze and water to the bottle until the level reaches the MIN mark. Do Not Over- fill the bottle by adding fluid above the MAX line. This may cause coolant to spill onto the ground during subsequent vehicle operation.
The 3.7L/4.7L/5.9L engine coolant degas system provides a quick method for determining the coolant level with out removing the radiator pressure cap. With a cold engine, observe the level of coolant in the degas bottle. The level should be in the COLD FILL RANGE. DO NOT OVERFILL the bottle by adding fluid above the COLD FILL RANGE. This may cause coolant to spill onto the ground during subsequent vehicle operation.
STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING
CLEANING
Drain the cooling system and refill with water. Run the engine with the radiator cap installed until the upper radiator hose is hot. Stop the engine and drain the water from system. If the water is dirty, fill the system with water, run the engine and drain the sys- tem. Repeat this procedure until the water drains clean.
REVERSE FLUSHING
Reverse flushing of the cooling system is the forc- ing of water through the cooling system. This is done
COOLING
7 - 17
using air pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty systems with evidence of partial plugging.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator inlet and outlet. Attach a section of the radiator hose to the radiator bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing gun.
Internal
CAUTION: radiator pressure must not exceed 138 kPa (20 psi) as damage to radiator may result.
Allow the radiator to fill with water. When the radiator is filled, apply air in short blasts. Allow the radiator to refill between blasts. Continue this reverse flushing until clean water flows out through the rear of the radiator cooling tube passages.
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 and attach a lead-away hose to the water pump inlet fitting.
CAUTION: On vehicles equipped with a heater water control valve, be sure the heater control valve is closed (heat off). This will prevent coolant flow with scale and other deposits from entering the heater core.
Connect the water supply hose and air supply hose to 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. Con- tinue until clean water flows through the lead away hose.
Remove the lead away hose, flushing gun, water supply hose and air supply hose. Remove the thermo- stat housing and install the thermostat. Install the thermostat housing with a replacement gasket. Refer to Thermostat Replacement. Connect the radiator hoses. Refill the cooling system with the correct anti- freeze/water mixture. Refer to Refilling the Cooling System.
CHEMICAL CLEANING
In some instances, use a radiator cleaner (Mopart Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid flushing operation.
COOLING
7 - 18
COOLING (Continued)CAUTION: Follow manufacturers instructions when using these products.
STANDARD PROCEDURE—DRAINING COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS (Fig. 6) OR LOOSEN THE RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
(1) With the engine cold, raise the vehicle on a
hoist and locate the radiator draincock.
NOTE: Radiator draincock is located on the left/ lower side of radiator facing to rear of vehicle.
(2) Attach one end of a hose to the draincock. Put the other end into a clean container. Remove the radiator cap, open the draincock and drain the cool- ing system.
(3) If draining the entire engine is required,
remove the cylinder block drain plugs.
DR
(1) Install
the cylinder block drain plugs
(if removed). Coat the threads with Mopart Thread Sealant with Teflon.
(2) Close the radiator draincock.
CAUTION: Failure to purge air from the cooling sys- tem can result in an overheating condition and severe engine damage.
(3) Fill system using a 50/50 mixture antifreeze and low mineral content water. Stop filling when the level in the degas bottle has reached the top of the COLD FILL RANGE.
(4) Start and operate the engine until the thermo- stat opens (upper radiator hose is warm to the touch).
(5) If necessary, add a 50/50 mixture of anti-freeze and water to the degass bottle to maintain the proper coolant level in the degas bottle.
(6) Install the radiator cap.
STANDARD PROCEDURE—DRAINING COOLING SYSTEM 5.9L/8.0L ENGINE
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAIN- COCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse. (1) Attach one end of a hose to the draincock. Put
the other end into a clean container.
(2) DO NOT REMOVE THE RADIATOR CAP when draining the coolant from the reservoir/over- flow tank. Open radiator draincock and when the tank is empty, remove the radiator cap and continue draining the cooling system.
(3) If draining the entire engine, remove the cylin-
der block drain plugs. Refer to (Fig. 7).
Fig.6DrainPlug-3.7L/4.7LEngine
1 - CYLINDER BLOCK DRAIN PLUG 2 - EXHAUST MANIFOLD AND HEAT SHIELD
STANDARD PROCEDURE - REFILLING COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE
DO NOT WASTE REUSABLE COOLANT. If the solution is clean, drain the coolant into a clean con- tainer for reuse.
STANDARD PROCEDURE—REFILLING COOLING SYSTEM 5.9L/8.0L ENGINE
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAIN- COCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse. Clean cooling system prior to refilling. (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(1) Install cylinder block drain plugs. Coat the
threads with Mopart Thread Sealant with Teflon.
(2) Close radiator petcock.
DR COOLING (Continued)
COOLING
7 - 19
STANDARD PROCEDURE—REFILLING COOLING SYSTEM 5.9L DIESEL ENGINE
(3) Fill cooling system with a 50/50 mixture of
(3) Fill coolant reserve/overflow tank to the FULL
Clean cooling system prior to refilling (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(1) Close radiator drain plug.
CAUTION: Due to the use of the one-way check valve, the engine must not be operating when refill- ing the cooling system.
NOTE: The diesel engine is equipped with two one- way check valves (jiggle pins). The check valves are used as a servicing feature and will vent air when the system is being filled. Water pressure (or flow) will hold the valves closed.
(2) Fill the cooling system with a 50/50 mixture of
water and antifreeze.
mark.
(4) Start and operate engine until
thermostat opens. Upper radiator hose should be warm to touch. (5) If necessary, add 50/50 water and antifreeze mixture to the coolant reserve/overflow tank to main- tain coolant level. This level should be between the ADD and FULL marks. The level in the reserve/over- flow tank may drop below the ADD mark after three or four warm-up and cool-down cycles.
STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes con- taminated, drain, flush, and replace with fresh prop- erly mixed coolant solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
For 5.9L engines, do not remove the radiator cap to add coolant to the system. When adding coolant to maintain the correct level, do so only at the reserve/ overflow bottle. Remove the radiator cap only for testing or when refilling the system after service. Removing the cap unnecessarily can cause loss of coolant and allow air to enter the system, which pro- duces corrosion.
Fig.7CylinderBlockDrainPlug-5.9LEngines
1 - BLOCK DRAIN PLUG
water and antifreeze.
on bottle.
(4) Fill coolant reserve/overflow tank to MAX mark
(5) Start and operate engine until
thermostat
opens (upper radiator hose warm to touch).
(6) If necessary, add a 50/50 water and antifreeze mixture to the coolant reserve/overflow tank. This is done to maintain coolant level between the MAX and MIN marks. The level in the reserve/overflow tank may drop below the MIN mark after three or four warm-up and cool-down cycles.
STANDARD PROCEDURE—DRAINING COOLING SYSTEM 5.9L DIESEL ENGINE
WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN PLUG WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
(1) Start the engine and place the heater control
temperature selector in the Full-On position.
(2) Turn the ignition off. (3) Do not remove radiator cap when draining cool- ant from reserve/overflow tank. Open radiator drain plug and when tank is empty, remove radiator cap. If the coolant reserve/overflow tank does not drain, (Refer to 7 - COOLING - DIAGNOSIS AND TEST- ING). The coolant need not be removed from tank unless the system is being refilled with fresh mix- ture.
(4) Remove radiator pressure cap.
COOLING
7 - 20
COOLING (Continued)DR
WARNING: DO NOT REMOVE OR LOOSEN THE RADIATOR CAP WITH THE COOLING SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM THE COOLANT OR HIGH PRESSURE STEAM CAN OCCUR.
SPECIFICATIONS -
SPECIFICATIONS
DESCRIPTION
SPECIFICATION
For 3.7L / 4.7L/5.9L engines, remove the radiator
cap from the coolant degas bottle to add coolant.
3.7/4.7L Engine
SPECIFICATIONS
TORQUE
5.7L Engine
5.9L Engine
DESCRIPTION
N·m
Ft.
In.
15.4L (16.2 qts.)- to the middle of the cold fill range 15.4L (16.2 qts.)- to the middle of the cold fill range 15.5L (16.3 qts.)- to the MIN mark after 3 warm up, cool down cycles 24L (25.3 qts.) 28L (29.5 qts.)
Automatic Belt Tensioner to Block—Bolts Automatic Belt Tensioner Pulley—Bolt Block Heater—Bolt Generator/Compressor Mounting Bracket—Bolts
# 1 and 2
# 3Fan Shroud to Radiator Mounting—Bolts Radiator to Support - Bolts Fan Blade to Viscous Fan Drive—Bolts Idler Pulley—Bolt Thermostat Housing—Bolts - All Except 5.9L Thermostat Housing—Bolts - 5.9L Power Steering Oil Cooler — Bolts Transmission Auxiliary Oil Cooler—Bolts Transmission Oil Cooler Tube Nuts Coolant Bottle — Bolts Transmission Oil Cooler to Transmission - 5.9L/46RE - Tube Nuts Transmission Oil Cooler to Transmission - 3.7L/4.7L/ 45RFE - Tube Nuts Water Pump—Bolts Water Pump — Bolts - 4.7L
41
61
54
408.5
2454
1323
31.5
8.5
31.5
2024
58Lbs.
Lbs.
8.0L Engine 5.9L Diesel Engine
30
45
—40
30
—— 18
40
—16
—
— 24
—
24
1818
43—
— 17
— — 55
75
—— 112
—
55
55
—75
— —
— —
SPECIAL TOOLS
COOLING
PliersConstantPressureHoseClamp-6094
3/8”QuickConnectReleaseTool-6935
SPANNERWRENCH—6958
DR COOLING (Continued)
COOLING
7 - 21
CoolingSystemPressureTester-7700A
AdapterPins8346
7 - 22
ACCESSORY DRIVE
ACCESSORY DRIVE
TABLE OF CONTENTS
page
DR
page
BELT TENSIONERS - 3.7L / 4.7L
DRIVE BELTS - 3.7L / 4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
. . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27BELT TENSIONERS - 5.9L
DRIVE BELTS - 5.9L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
. . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31BELT TENSIONERS - 5.9L DIESEL
DRIVE BELTS - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25DIAGNOSIS AND TESTING—ACCESSORY
DRIVE BELT
. . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34BELT TENSIONERS - 3.7L / 4.7L DESCRIPTION
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, rate, and greatly reduced belt life.
reduced generator output
It is not necessary to adjust belt tension on the 3.7L or 4.7L engine. These engines are equipped with an automatic belt tensioner (Fig. 1). The tensioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 3.7L or 4.7L engines.
OPERATION
The automatic belt tensioner maintains belt ten- sion by using internal spring pressure, a pivoting arm and pulley to press against the drive belt.
REMOVAL
On 3.7L and 4.7L engines, the tensioner is equipped with an indexing tang on back of ten- sioner and an indexing stop on tensioner hous- ing. If a new belt is being installed, tang must be within approximately 24 mm (.94 inches) of
Fig.1AUTOMATICBELTTENSIONER
1 - AUTOMATIC TENSIONER ASSEMBLY
indexing stop. Belt is considered new if it has been used 15 minutes or less.
If the above specification cannot be met, check for: † The wrong belt being installed (incorrect length/ width)† Worn bearings on an engine accessory (A/C com- pressor, power steering pump, water pump, idler pul- ley or generator)
† A pulley on an engine accessory being loose † Misalignment of an engine accessory † Belt incorrectly routed.
DR BELT TENSIONERS - 3.7L / 4.7L (Continued)
NOTE: A used belt should be replaced if tensioner indexing arrow has moved to the minimum tension indicator. Tensioner travel stops at this point.
ACCESSORY DRIVE
7 - 23
BELT TENSIONERS - 5.9L DESCRIPTION
(1) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(2) Remove tensioner assembly from mounting
bracket (Fig. 2).
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, rate, and greatly reduced belt life.
reduced generator output
It is not necessary to adjust belt tension on the 3.9L or 5.9L engines. These engines are equipped with an automatic belt tensioner (Fig. 3). The ten- sioner maintains correct belt tension at all times. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 3.9L or 5.9L engines.
Fig.2AUTOMATICBELTTENSIONER-3.7L/4.7L
ENGINE
1 - TIMING CHAIN COVER 2 - BOLT TORQUE TO 41 N·m (30 FT LBS) 3 - AUTOMATIC BELT TENSIONER
WARNING: BECAUSE OF HIGH SPRING PRES- SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO- MATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
Fig.3AutomaticBeltTensioner-5.9LEngines
1 - AUTOMATIC TENSIONER 2 - COIL AND BRACKET 3 - SCREW AND WASHER
OPERATION
The automatic belt tensioner maintains belt ten- sion by using internal spring pressure, a pivoting arm and pulley to press against the drive belt.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES- SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO- MATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY (EXCEPT FOR PULLEY).
(1) Install pulley and pulley bolt
to tensioner.
Tighten bolt to 61 N·m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner. Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt to 41
N·m (30 ft. lbs.).(3) Install accessory drive belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(4) Check belt indexing marks (Fig. 1).
(1) Remove accessory drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(2) Disconnect wiring and secondary cable from
ignition coil. (3) Remove
from coil mounting bracket (two bolts). Do not remove coil mounting bracket from cylinder head.
ignition coil
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 4).
ACCESSORY DRIVE
7 - 24
BELT TENSIONERS - 5.9L (Continued)DR
BELT TENSIONERS - 5.9L DIESEL DESCRIPTION
Drive belts on all engines are equipped with a spring loaded automatic belt tensioner (Fig. 5). This tensioner maintains constant belt tension at all times and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner.
Fig.4TensionerIndexingMarksAndMountingNut 1 - TENSIONER ASSEMBLY 2 - TENSIONER MOUNTING NUT 3 - INDEXING ARROW 4 - INDEXING MARK
(5) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt
to tensioner.
Tighten bolt to 61 N·m (45 ft. lbs.) torque.
tensioner
(2) Install
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.
assembly
(3) Connect all wiring to ignition coil.
CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued.
(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.(5) Install drive belt. (Refer to 7 - COOLING/AC- INSTALLA-
CESSORY DRIVE/DRIVE BELTS - TION).
(6) Check belt indexing marks (Fig. 4).
Fig.5Belt
1 - GENERATOR 2 - WATER PUMP 3 - IDLER 4 - POWER STEERING PUMP 5 - AUTOMATIC TENSIONER 6 - A/C COMPRESSOR
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt tension using a coiled spring within the tensioner housing. The spring applies pressure to the tensioner arm pressing the arm into the belt, tensioning the belt.
DR BELT TENSIONERS - 5.9L DIESEL (Continued) REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES- SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO- MATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
(1) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 6) and
remove tensioner.
ACCESSORY DRIVE
7 - 25
DRIVE BELTS - 3.7L / 4.7L DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 7), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not nor- mal. Any belt with cracks running along a rib must be replaced (Fig. 7). Also replace the belt if it has excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
Fig.6AUTOMATICBELTTENSIONERDIESEL
ENGINE-TYPICAL
1 - GENERATOR 2 - WATER PUMP 3 - IDLER 4 - POWER STEERING PUMP 5 - AUTOMATIC TENSIONER 6 - A/C COMPRESSOR
INSTALLATION
tensioner
(1) Install
to mounting bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 N·m (32 ft. lbs.) torque.
assembly
(2) Install drive belt (Refer to 7 - COOLING/AC- INSTALLA-
CESSORY DRIVE/DRIVE BELTS - TION).
Fig.7BeltWearPatterns
1 - NORMAL CRACKS BELT OK 2 - NOT NORMAL CRACKS REPLACE BELT
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play.
ACCESSORY DRIVE
7 - 26
DRIVE BELTS - 3.7L / 4.7L (Continued)DR
ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSES
CORRECTION
RIB CHUNKING (One or more ribs has separated from belt body)
1. Foreign objects imbedded in pulley grooves.
1. Remove foreign objects from pulley grooves. Replace belt.
RIB OR BELT WEAR
1. Pulley misaligned
2. Installation damage
2. Replace belt
1. Align pulley(s)
BELT SLIPS
LONGITUDAL BELT CRACKING
9GROOVE JUMPING9
(Belt does not maintain correct position on pulley)BELT BROKEN (Note: Identify and correct problem before new belt is installed)
2. Abrasive environment
3. Rusted pulley(s) 4. Sharp or jagged pulley groove tips 5. Belt rubber deteriorated
2. Clean pulley(s). Replace belt if necessary 3. Clean rust from pulley(s) 4. Replace pulley. Inspect belt.
5. Replace belt
1. Belt slipping because of insufficient tension
1. Inspect/Replace tensioner if necessary
2. Belt or pulley exposed to substance that has reduced friction (belt dressing, oil, ethylene glycol) 3. Driven component bearing failure (seizure) 4. Belt glazed or hardened from heat and excessive slippage
2. Replace belt and clean pulleys
3. Replace faulty component or bearing 4. Replace belt.
1. Belt has mistracked from pulley groove
1. Replace belt
2. Pulley groove tip has worn away rubber to tensile member
2. Replace belt
1. Incorrect belt tension
2. Pulley(s) not within design tolerance 3. Foreign object(s) in grooves
4. Pulley misalignment 5. Belt cordline is broken
1. Incorrect belt tension
2. Tensile member damaged during belt installation 3. Severe misalignment 4. Bracket, pulley, or bearing failure
1. Inspect/Replace tensioner if necessary
2. Replace pulley(s)
3. Remove foreign objects from grooves 4. Align component 5. Replace belt
1. Replace Inspect/Replace tensioner if necessary 2. Replace belt
3. Align pulley(s) 4. Replace defective component and belt
DR DRIVE BELTS - 3.7L / 4.7L (Continued)
ACCESSORY DRIVE
7 - 27
CONDITION
POSSIBLE CAUSES
CORRECTION
NOISE (Objectionable squeal, squeak, or rumble is heard or felt while drive belt is in operation)
TENSION SHEETING FABRIC FAILURE (Woven fabric on outside, circumference of belt has cracked or separated from body of belt)
CORD EDGE FAILURE (Tensile member exposed at edges of belt or separated from belt body)
1. Incorrect belt tension
2. Bearing noise 3. Belt misalignment 4. Belt to pulley mismatch 5. Driven component induced vibration
1. Tension sheeting contacting stationary object
2. Excessive heat causing woven fabric to age 3. Tension sheeting splice has fractured
1. Incorrect belt tension
2. Belt contacting stationary object 3. Pulley(s) out of tolerance 4. Insufficient adhesion between tensile member and rubber matrix
1. Inspect/Replace tensioner if necessary
2. Locate and repair 3. Align belt/pulley(s) 4. Install correct belt 5. Locate defective driven component and repair
1. Correct rubbing condition
2. Replace belt
3. Replace belt
1. Inspect/Replace tensioner if necessary 2. Replace belt 3. Replace pulley 4. Replace belt
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREEARM POSITION, SEVER DAM- AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt ten- sioner.
(1) Disconnect negative battery cable from battery. (2) Rotate belt tensioner until it contacts it’s stop. Remove belt, then slowly rotate the tensioner into the freearm position. (Fig. 8).
INSTALLATION
Belt tension is not adjustable. Belt adjustment is maintained by an automatic ( spring load ) belt ten- sioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Fig. 8).
(2) Install new belt (Fig. 8). Route the belt around all pulleys except the idler pulley. Rotate the ten- sioner arm until it contacts it’s stop position. Route the belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys.
(3) With the drive belt installed, inspect the belt wear indicator (Fig. 9). On 4.7L Engines only, the gap between the tang and the housing stop (measure- ment A) must not exceed 24 mm (.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt.
ACCESSORY DRIVE
7 - 28
DRIVE BELTS - 3.7L / 4.7L (Continued)DR
DRIVE BELTS - 5.9L DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 10), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not nor- mal. Any belt with cracks running along a rib must be replaced (Fig. 10). Also replace the belt if it has excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
Fig.8BELTROUTING3.7L/4.7L
1 - GENERATOR PULLEY 2 - ACCESSORY DRIVE BELT 3 - POWER STEERING PUMP PULLEY 4 - CRANKSHAFT PULLEY 5 - IDLER PULLEY 6 - TENSIONER 7 - A/C COMPRESSOR PULLEY 8 - WATER PUMP PULLEY
Fig.9AccessoryDriveBeltWearIndicator–4.7L
1 - AUTOMATIC TENSIONER ASSEMBLY
Engine
Fig.10BeltWearPatterns
1 - NORMAL CRACKS BELT OK 2 - NOT NORMAL CRACKS REPLACE BELT
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play.
DR DRIVE BELTS - 5.9L (Continued)
ACCESSORY DRIVE
7 - 29
ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSES
CORRECTION
RIB CHUNKING (One or more ribs has separated from belt body)
1. Foreign objects imbedded in pulley grooves.
1. Remove foreign objects from pulley grooves. Replace belt.
RIB OR BELT WEAR
1. Pulley misaligned
2. Installation damage
2. Replace belt
1. Align pulley(s)
BELT SLIPS
LONGITUDAL BELT CRACKING
9GROOVE JUMPING9
(Belt does not maintain correct position on pulley)BELT BROKEN (Note: Identify and correct problem before new belt is installed)
2. Abrasive environment
3. Rusted pulley(s) 4. Sharp or jagged pulley groove tips 5. Belt rubber deteriorated
2. Clean pulley(s). Replace belt if necessary 3. Clean rust from pulley(s) 4. Replace pulley. Inspect belt.
5. Replace belt
1. Belt slipping because of insufficient tension
1. Inspect/Replace tensioner if necessary
2. Belt or pulley exposed to substance that has reduced friction (belt dressing, oil, ethylene glycol) 3. Driven component bearing failure (seizure) 4. Belt glazed or hardened from heat and excessive slippage
2. Replace belt and clean pulleys
3. Replace faulty component or bearing 4. Replace belt.
1. Belt has mistracked from pulley groove
1. Replace belt
2. Pulley groove tip has worn away rubber to tensile member
2. Replace belt
1. Incorrect belt tension
2. Pulley(s) not within design tolerance 3. Foreign object(s) in grooves
4. Pulley misalignment 5. Belt cordline is broken
1. Incorrect belt tension
2. Tensile member damaged during belt installation 3. Severe misalignment 4. Bracket, pulley, or bearing failure
1. Inspect/Replace tensioner if necessary
2. Replace pulley(s)
3. Remove foreign objects from grooves 4. Align component 5. Replace belt
1. Replace Inspect/Replace tensioner if necessary 2. Replace belt
3. Align pulley(s) 4. Replace defective component and belt
ACCESSORY DRIVE
7 - 30
DRIVE BELTS - 5.9L (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
NOISE (Objectionable squeal, squeak, or rumble is heard or felt while drive belt is in operation)
TENSION SHEETING FABRIC FAILURE (Woven fabric on outside, circumference of belt has cracked or separated from body of belt)
CORD EDGE FAILURE (Tensile member exposed at edges of belt or separated from belt body)
1. Incorrect belt tension
2. Bearing noise 3. Belt misalignment 4. Belt to pulley mismatch 5. Driven component induced vibration
1. Tension sheeting contacting stationary object
2. Excessive heat causing woven fabric to age 3. Tension sheeting splice has fractured
1. Incorrect belt tension
2. Belt contacting stationary object 3. Pulley(s) out of tolerance 4. Insufficient adhesion between tensile member and rubber matrix
1. Inspect/Replace tensioner if necessary
2. Locate and repair 3. Align belt/pulley(s) 4. Install correct belt 5. Locate defective driven component and repair
1. Correct rubbing condition
2. Replace belt
3. Replace belt
1. Inspect/Replace tensioner if necessary 2. Replace belt 3. Replace pulley 4. Replace belt
REMOVAL
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.
CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Refer to Automatic Belt Tensioner in this group.
Drive belts on these engines are equipped with a spring loaded automatic belt tensioner (Fig. 11). This belt tensioner will be used on all belt configurations, such as with or without power steering or air condi- tioning. For more information, (Refer to 7 - COOL- ING/ACCESSORY DRIVE/BELT TENSIONERS - DESCRIPTION).
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 11).
(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 vehicle.
Fig.11BeltTensioner-5.9LGasEngines
1 - IDLER PULLEY 2 - TENSIONER 3 - FAN BLADE
DR DRIVE BELTS - 5.9L (Continued) INSTALLATION
CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 12) for correct engine belt routing. The correct belt with correct length must be used.
(Fig. 13)
ACCESSORY DRIVE
7 - 31
(1) Position drive belt over all pulleys except idler pulley. This pulley is located between generator and A/C compressor.
(2) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 11).
(3) 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.
(4) Check belt indexing marks (Refer to 7 - COOL- ING/ACCESSORY DRIVE/BELT TENSIONERS - DESCRIPTION).
Fig.12BeltRouting-5.9LEngineswithA/C
1 - GENERATOR PULLEY 2 - A/C PULLEY 3 - POWER STEERING PULLEY 4 - CRANKSHAFT PULLEY 5 - WATER PUMP PULLEY 6 - TENSIONER PULLEY 7 - IDLER PULLEY
Fig.13BeltRouting-5.9LEnginesWithoutA/C
1 - GENERATOR PULLEY 2 - IDLER PULLEY 3 - POWER STEERING PULLEY 4 - CRANKSHAFT PULLEY 5 - WATER PUMP PULLEY 6 - TENSIONER PULLEY
DRIVE BELTS - 5.9L DIESEL DIAGNOSIS AND TESTING—ACCESSORY DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 14), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not nor- mal. Any belt with cracks running along a rib must be replaced (Fig. 14). Also replace the belt if it has excessive wear, frayed cords or severe glazing.
ACCESSORY DRIVE
7 - 32
DRIVE BELTS - 5.9L DIESEL (Continued)Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
DR
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play.
Fig.14BeltWearPatterns
1 - NORMAL CRACKS BELT OK 2 - NOT NORMAL CRACKS REPLACE BELT
ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSES
CORRECTION
RIB CHUNKING (One or more ribs has separated from belt body)
1. Foreign objects imbedded in pulley grooves.
1. Remove foreign objects from pulley grooves. Replace belt.
RIB OR BELT WEAR
1. Pulley misaligned
2. Installation damage
BELT SLIPS
2. Abrasive environment
3. Rusted pulley(s) 4. Sharp or jagged pulley groove tips 5. Belt rubber deteriorated
1. Belt slipping because of insufficient tension 2. Belt or pulley exposed to substance that has reduced friction (belt dressing, oil, ethylene glycol) 3. Driven component bearing failure (seizure) 4. Belt glazed or hardened from heat and excessive slippage
2. Replace belt
1. Align pulley(s)
2. Clean pulley(s). Replace belt if necessary 3. Clean rust from pulley(s) 4. Replace pulley. Inspect belt.
5. Replace belt
1. Inspect/Replace tensioner if necessary 2. Replace belt and clean pulleys
3. Replace faulty component or bearing 4. Replace belt.
DR DRIVE BELTS - 5.9L DIESEL (Continued)
ACCESSORY DRIVE
7 - 33
CONDITION
POSSIBLE CAUSES
CORRECTION
LONGITUDAL BELT CRACKING
1. Belt has mistracked from pulley groove
1. Replace belt
2. Pulley groove tip has worn away rubber to tensile member
2. Replace belt
9GROOVE JUMPING9
(Belt does not maintain correct position on pulley)BELT BROKEN (Note: Identify and correct problem before new belt is installed)
NOISE (Objectional squeal, squeak, or rumble is heard or felt while drive belt is in operation)
TENSION SHEETING FABRIC FAILURE (Woven fabric on outside, circumference of belt has cracked or separated from body of belt)
CORD EDGE FAILURE (Tensile member exposed at edges of belt or separated from belt body)
1. Incorrect belt tension
2. Pulley(s) not within design tolerance 3. Foreign object(s) in grooves
4. Pulley misalignment 5. Belt cordline is broken
1. Incorrect belt tension
2. Tensile member damaged during belt installation 3. Severe misalignment 4. Bracket, pulley, or bearing failure
1. Incorrect belt tension
2. Bearing noise 3. Belt misalignment 4. Belt to pulley mismatch 5. Driven component induced vibration
1. Tension sheeting contacting stationary object
2. Excessive heat causing woven fabric to age 3. Tension sheeting splice has fractured
1. Incorrect belt tension
2. Belt contacting stationary object 3. Pulley(s) out of tolerance 4. Insufficient adhesion between tensile member and rubber matrix
1. Inspect/Replace tensioner if necessary
2. Replace pulley(s)
3. Remove foreign objects from grooves 4. Align component 5. Replace belt
1. Replace Inspect/Replace tensioner if necessary
2. Replace belt
3. Align pulley(s) 4. Replace defective component and belt
1. Inspect/Replace tensioner if necessary
2. Locate and repair 3. Align belt/pulley(s) 4. Install correct belt 5. Locate defective driven component and repair
1. Correct rubbing condition
2. Replace belt
3. Replace belt
1. Inspect/Replace tensioner if necessary 2. Replace belt 3. Replace pulley 4. Replace belt
ACCESSORY DRIVE
7 - 34
DRIVE BELTS - 5.9L DIESEL (Continued)NOTE: The engine speed sensor face is very close to the accessory drive belt. Inspect engine speed sensor and wire harness for damage when acces- sory drive belt has been replaced due to failure or abnormal conditions.
REMOVAL
CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Refer to Automatic Belt Tensioner in this group.
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.
Drive belts on diesel engines are equipped with a spring loaded automatic belt tensioner. displays the tensioner for vehicles without air conditioning. This belt tensioner will be used on all belt config- urations, such as with or without air conditioning. For more information, (Refer to 7 - COOLING/AC- CESSORY DRIVE/BELT TENSIONERS - DESCRIP- TION).
(1) A 1/2 inch square hole is provided in the auto- matic belt tensioner. Attach a 1/2 inch drive-long handle ratchet to this hole.
(2) Rotate ratchet and tensioner assembly clock- wise (as viewed from front) until tension has been relieved from belt.
(3) Remove belt from water pump pulley first. (4) Remove belt from vehicle.
INSTALLATION
CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may
DR
overheat due to water pump rotating in wrong direction. Refer to (Fig. 15) for correct engine belt routing. The correct belt with correct length must be used.
(1) Position drive belt over all pulleys except
water pump pulley.
(2) Attach a 1/2 inch ratchet to tensioner. (3) Rotate ratchet and belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys.
Fig.15BeltRouting–5.9LDieselEngine
1 - GENERATOR PULLEY 2 - WATER PUMP PULLEY 3 - IDLER PULLEY 4 - POWER STEERING PUMP PULLEY 5 - RADIATOR FAN PULLEY 6 - CRANKSHAFT PULLEY 7 - AUTOMATIC TENSIONER 8 - A/C COMPRESSOR PUMP PULLEY
DR
ENGINE
7 - 35
ENGINE
TABLE OF CONTENTS
page
page
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT . . . . . . . 36
DESCRIPTION - HOAT COOLANT . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38COOLANT RECOVERY CONTAINER-5.9L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38COOLANT DEGAS CONTAINER-3.7L/4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39RADIATOR FAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40RADIATOR FAN - 5.9L DIESEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41ENGINE BLOCK HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIAGNOSIS AND TESTING — ENGINE BLOCKHEATER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43ENGINE BLOCK HEATER - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47ENGINE COOLANT THERMOSTAT- 5.7L/5.9L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSIS AND TESTING—THERMOSTAT . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49ENGINE COOLANT THERMOSTAT - 3.7L/4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DIAGNOSIS AND TESTING—THERMOSTAT . . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DIAGNOSIS AND TESTING—THERMOSTAT . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53FAN DRIVE VISCOUS CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIAGNOSIS AND TESTING - VISCOUS FANDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DIAGNOSIS AND TESTING - ELECTRONICLYCONTOLLED VISCOUS FAN DRIVE
. . . . . . . 56
RADIATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DIAGNOSIS AND TESTING—RADIATORCOOLANT FLOW . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58RADIATOR - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
DIAGNOSIS AND TESTING—RADIATORCOOLANT FLOW . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—RADIATOR
CAP-TO-FILLER NECK SEAL . . . . . . . . . . . . . 61
DIAGNOSIS AND TESTING - RADIATOR
CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 627 - 36
ENGINE
WATER PUMP - 5.9L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DIAGNOSIS AND TESTING—WATER PUMP . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64WATER PUMP - 3.7L/4.7L
DESCRIPTION
DESCRIPTION—WATER PUMP . . . . . . . . . . . 64
DESCRIPTION—WATER PUMP BYPASS . . . . 64OPERATION
OPERATION—WATER PUMP OPERATION—WATER PUMP BYPASS
. . . . . . . . . . . . 64
. . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66WATER PUMP - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 67
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyl- ene-glycol.
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, 5 year/ 100,000Mil;e Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F).
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle oper- ating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 per- cent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protec- tion against freezing is provided with a 68% anti- freeze concentration, which prevents freezing down to
DR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DIAGNOSIS AND TESTING—WATER PUMP . . . 67
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68WATER PUMP INLET TUBE - 5.9L
REMOVAL
REMOVAL - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING . . . . . . . . . . . . . . . 68
REMOVAL - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING . . . . . . . . . . . 69
INSTALLATION
INSTALLATION - WATER PUMP BYPASS
HOSE WITH AIR CONDITIONING . . . . . . . . . 70
INSTALLATION - WATER PUMP BYPASS
HOSE WITHOUT AIR CONDITIONING . . . . . . 70
WATER PUMP - 5.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71-67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause for- mation of additive deposits in the system, as the cor- rosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149° C (300° F). This temperature is hot enough to melt plastic and soften solder. The increased temper- ature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F ).
PROPYLENE-GLYCOL MIXTURES
It’s overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol’s freeze point. The boiling point (protection against summer boil-over) of propy- lene-glycol is 125° C (257° F ) at 96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Pro- pylene glycol also has poorer heat transfer character- istics than ethylene glycol. This can increase cylinder head temperatures under certain conditions.Propylene-glycol/ethylene-glycol Mixtures
can cause the destabilization of various corrosion inhibi- tors, causing damage to the various cooling system
DR COOLANT (Continued)
components. Also, once ethylene-glycol and propy- lene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and spe- cific gravity differ between ethylene glycol and propy- lene glycol.
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWAL- LOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMIT- ING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection.
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.
Mopart
Antifreeze/Coolant,
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Year/100,000 Mile Formula (MS-9769), or the equiva- lent ethylene-glycol base coolant with organic corro- sion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solu- tion.
CAUTION: Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of
Antifreeze/Coolant,
MoparT
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coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mix- tures follows:
Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for pur- pose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The
corrosion inhibiting additives in ethylene-glycol need the pres- ence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plas- tic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recom- mended mixture, it provides protection against freez- ing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year- round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec- tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher per- centage of antifreeze can cause the engine to over- heat 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 ethyl- ene-glycol.
COOLANT SELECTION AND ADDITIVES
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.
-37°C (-35°F). If
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COOLANT (Continued)CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
OPERATION
Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol cool- ant prevents water present in the cooling system from freezing within temperatures indicated by mix- ture ratio of coolant to water.
COOLANT RECOVERY CONTAINER-5.9L DESCRIPTION
The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high tempera- ture plastic (Fig. 1).
DR
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. Cool- ant will then be drawn from the coolant tank and returned to a proper level in the radiator.
REMOVAL
(1) Remove recovery hose from radiator. (2) Remove the coolant container to fan shroud
mounting bolt.
(3) Tilt the container backward towards the engine to disengage the mounting pin locking features and lift the container away from the fan shroud (Fig. 1).
INSTALLATION
(1) Align the coolant container mounting pins into the slots on the fan shroud and push the container onto the fan shroud.
(2) Secure the container to the fan shroud with the
bolt. Tighten to 8.5N·m (75 in-lbs).
NOTE: Ensure that mounting pins has engaged.
the locking feature on the
(3) Connect the recovery hose to the radiator (Fig.
1).
COOLANT DEGAS CONTAINER-3.7L/4.7L DESCRIPTION
The coolant degas container is mounted on top of the fan shroud and is made of high temperatyre plas- tic (Fig. 2).
OPERATION
The coolant degas system works in parallel with the radiator. It is fed through a vent line connected to the top of the radiator inlet tank and returns to the engine/coolant pump via the heater return hoses. This plumbing arrangement, together with the inlet thermostat, provides for constant flow through the degas container whenever the engine is running. The air space in the top of the degas container serves sev- eral functions. It provides a volume for the expansion of coolant during engine operation. It provides a space for quick de-aeration of the coolant. Since the container is the highest point in the cooling system, any air trapped in the coolant will quickly be trans- ported to the degas container and be separated out.
Fig.1CoolantRecoveryBottle—5.9L
1 - SCREW 2 - COOLANT RECOVERY CONTAINER 3 - RADIATOR/RADIATOR CAP 4 - FAN SHROUD
OPERATION
The coolant reserve/overflow system works in con- junction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides
DR COOLANT DEGAS CONTAINER-3.7L/4.7L (Continued)
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