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-
ing at this point.
(2) Check for switch continuity with an ohmmeter while operating clutch pedal up and down. Continu- ity should be broken and reapplied each time pedal is pressed.
(3) If continuity is not present, or is always present at any pedal position, replace switch. Switch is not serviced separately. Replace clutch master cylinder.
Fig.22LOCATION,CLUTCHPEDALPOSITION
SWITCH
1 - CLUTCH MASTER CYLINDER 2 - CLUTCH PEDAL POSITION SWITCH
Fig.23CLUTCHSWITCHTESTPOINT
1 - PEDAL SUPPORT BRACKET 2 - ELECTRICAL CONNECTOR
DR
COOLING
7 - 1
COOLING
TABLE OF CONTENTS
page
page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3.7L/4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - COOLING SYSTEM FLOW -
5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION—COOLING SYSTEM FLOW -
5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - HOSE CLAMPS . . . . . . . . . . . 3OPERATION
OPERATION—COOLING SYSTEM . . . . . . . . . 3
OPERATION—HOSE CLAMPS . . . . . . . . . . . . 5DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ON-BOARD
STANDARD PROCEDURE - COOLING
SYSTEM CLEANING/REVERSE FLUSHING . . 17
STANDARD PROCEDURE—DRAINING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE . . 18
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE . . 18
STANDARD PROCEDURE—DRAINING
COOLING SYSTEM 5.9L/8.0L ENGINE . . . . . . 18
STANDARD PROCEDURE—REFILLING
COOLING SYSTEM 5.9L/8.0L ENGINE . . . . . . 18
STANDARD PROCEDURE—DRAINING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
STANDARD PROCEDURE—REFILLING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
DIAGNOSTICS (OBD) . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE - ADDING
DIAGNOSIS AND TESTING—COOLING
ADDITIONAL COOLANT. . . . . . . . . . . . . . . . . 19
SYSTEM - TESTING FOR LEAKS . . . . . . . . . . 5
SPECIFICATIONS
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIESEL ENGINE . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . 17
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS - . . . . . . . . . . . . . . . . . . . . 20SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 22
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 72COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW 3.7L/4.7L ENGINE
The cooling system regulates engine operating tem- perature. It allows the engine to reach normal oper- ating temperature as quickly as possible. It also maintains normal operating temperature and pre- vents overheating.
The cooling system provides a means of heating the passenger compartment and cooling the auto- matic transmission fluid (if equipped). The cooling system is pressurized and uses a centrifugal water pump to circulate coolant through the system and a coolant deaeration and reserve system that utilizes a pressurized degas bottle (hot bottle).
An optional factory installed maximum duty cool- ing package is available on most models. This pack- age will provide additional cooling capacity for
vehicles used under extreme conditions such as trailer towing in high ambient temperatures (Fig. 1).
DESCRIPTION - COOLING SYSTEM FLOW - 5.9L ENGINE
The cooling system regulates engine operating tem- perature. It allows the engine to reach normal oper- ating temperature as quickly as possible. It also maintains normal operating temperature and pre- vents overheating.
The cooling system also provides a means of heat- ing the passenger compartment and cooling the auto- matic transmission fluid (if equipped). The cooling system uses a coolant recovery / reserve system that utilizes an ambient overflow bottle.
An optional factory installed maximum duty cool- ing package is available on most models. This pack- age will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures (Fig. 2).
COOLING
7 - 2
COOLING (Continued)DR
1 - LH CYL. HEAD 2 - BLEED 3 - THERMOSTAT LOCATION 4 - RH CYL. HEAD 5 - RH BANK CYL. BLOCK
Fig.1EngineCoolingSystemFlow-3.7L/4.7L 6 - LH BANK CYL. BLOCK 7 - COOLANT TEMP. SENSOR 8 - FROM HEATER CORE 9 - TO HEATER CORE
DESCRIPTION—COOLING SYSTEM FLOW - 5.9L DIESEL
The diesel engine cooling system consists of : † Cross-flow radiator † Belt driven water pump † Belt driven mechanical cooling fan † Electronic viscous fan drive † Fan shroud † Radiator pressure cap
† Vertically mounted thermostat † Coolant reserve/recovery system † Transmission oil cooler † Coolant Coolant flow circuits for the 5.9L diesel engine are
shown in (Fig. 3).
DR COOLING (Continued)
COOLING
7 - 3
1 - HEATER 2 - BYPASS*
Fig.2ENGINECOOLINGSYSTEMFLOW-5.9L 3 - CROSSFLOW RADIATOR 4 - THERMOSTAT LOCATION
DESCRIPTION - HOSE CLAMPS
The cooling system utilizes
spring type hose clamps. If a spring type clamp replacement is neces- sary, replace with the original Mopart equipment spring type clamp.
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only a original equipment clamp with matching number or letter and ensure the clamp has the same size width (Fig. 4).
OPERATION
OPERATION—COOLING SYSTEM
The cooling system regulates engine operating tem- perature. It allows the engine to reach normal oper- ating temperature as quickly as possible. It also maintains normal operating temperature and pre- vents overheating.
The cooling system also provides a means of heat- ing the passenger compartment and cooling the auto- matic transmission fluid (if equipped). The cooling
COOLING
7 - 4
COOLING (Continued)DR
Fig.3CoolingSystemCirculation—DieselEngine
DR COOLING (Continued)
COOLING
7 - 5
† If an open or shorted condition has developed in the electronically controlled viscous fan clutch circuit, a Diagnostic Trouble Code (DTC) can be set. † If fan speed is not detected a DTC will be set. † Coolant temperature sensor circuit problems can
set a DTC.
If the problem is sensed in a monitored circuit often enough to indicated an actual problem, a DTC is stored. The DTC will be stored in the ECM mem- ory for eventual display to the service technician. (Refer to 25 - EMISSIONS CONTROL - DESCRIP- TION).
Fig.4SpringClampSizeLocation
1 - SPRING CLAMP SIZE LOCATION
system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system.
5.9L, 5.9L Diesel, and 8.0L engines utilize an ambient overflow bottle for coolant recovery/reserve. The 3.7L and 4.7L engines utilize a pressurized degas bottle for coolant deaeration and reserve. This degas bottle has coolant flowing through it continu- ously, supplied by a vent in the hot side radiator tank and returning to the heater return hose.
An optional factory installed maximum duty cool- ing package is available on most models. This pack- age will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures.
OPERATION—HOSE CLAMPS
The spring type hose clamp applies constant ten- sion on a hose connection. To remove a spring type hose clamp, only use constant tension clamp pliers designed to compress the hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ON-BOARD DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Engine Control Module (ECM) has been pro- grammed to monitor certain cooling system compo- nents:† If the engine has remained cool for too long a period, such as with a stuck open thermostat, a Diag- nostic Trouble Code (DTC) can be set.
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC’s and to obtain cooling system data, (Refer to 25 - EMISSIONS CONTROL - DESCRIP- TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRBIIIt scan tool to erase a DTC. Refer to the appropriate Powertrain Diagnostic Procedures ser- vice information for operation of the DRBIIIt scan tool.
DIAGNOSIS AND TESTING—COOLING SYSTEM - TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the parts department that can be added to cooling sys- tem. The additive is highly visible under ultraviolet light (black light). Pour one ounce of additive into cooling system. Place heater control unit in HEAT position. Start and operate the engine until the radi- ator upper hose is warm to the touch. Aim the com- mercially available black light tool at the components to be checked. If leaks are present, the black light will cause the additive to glow a bright green color. The black light can be used in conjunction with a pressure tester to determine if any external leaks exist (Fig. 5).
PRESSURE TESTER METHOD
The engine should be at normal operating temper- ature. Recheck the system cold if the cause of coolant loss is not located during the warm engine examina- tion.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING.
Carefully remove the radiator pressure cap from the filler neck and check the coolant level. Push down on the cap to disengage it from the stop tabs. Wipe the inside of the filler neck and examine the
COOLING
7 - 6
COOLING (Continued)Fig.5LeakDetectionUsingBlackLight—Typical 1 - TYPICAL BLACK LIGHT TOOL
DR
Drops Quickly: Indicates that serious leakage is occurring. Examine the system for external leakage. If leaks are not visible, inspect for internal leakage. Large radiator leak holes should be repaired by a reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove the 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 the engine dipstick and inspect for water globules. Also inspect the transmission dipstick for water globules and transmission fluid cooler for leak- age.
WARNING: WITH RADIATOR PRESSURE TESTER TOOL INSTALLED ON RADIATOR, DO NOT ALLOW PRESSURE TO EXCEED 145 kPa (21 PSI). PRES- SURE 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.
lower inside sealing seat for nicks, cracks, paint, dirt and solder residue. Inspect the radiator-to- reserve/ overflow tank hose for internal obstructions. Insert a wire through the hose to be sure it is not obstructed. Inspect the cams on the outside of the filler neck. If the cams are damaged, seating of the pressure cap valve and tester seal will be affected.
Attach pressure tester (7700 or an equivalent) to
radiator filler neck.
Operate the tester pump to apply 103.4 kPa (15
psi) pressure to the system. If the hoses enlarge excessively or bulges while testing, replace as neces- sary. Observe the gauge pointer and determine the condition of the cooling system according to following criteria:Holds Steady: If the pointer remains steady for two minutes, serious coolant leaks are not present in system. However, there could be an internal leak that does not appear with normal system test pres- sure. If it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or perform Internal Leakage Test. Refer to INTER- NAL LEAKAGE INSPECTION.
Drops Slowly: Indicates a small leak or seepage is occurring. Examine all of the connections for seep- age or slight leakage with a flashlight. Inspect the radiator, hoses, gasket edges and heater. Seal the small leak holes with a Sealer Lubricant (or equiva- lent). Repair the leak holes and inspect the system again with pressure applied.
Operate the engine without the pressure cap on the radiator until the thermostat opens. Attach a Pressure Tester to the filler neck. If pressure builds up quickly it indicates a combustion leak exists. This is usually the result of a cylinder head gasket leak or crack in engine. Repair as necessary.
If there is not an immediate pressure increase, pump the Pressure Tester. Do this until indicated pressure is within system range of 110 kPa (16 psi). Fluctuation of the gauge pointer indicates compres- sion or combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic converter, do not short out cylinders to isolate com- pression leak.
If the needle on dial of the pressure tester does not fluctuate, race engine a few times to check for an abnormal amount of coolant or steam. This would be emitting from exhaust pipe. Coolant or steam from exhaust pipe may indicate a faulty cylinder head gas- ket, cracked engine cylinder block or cylinder head. A convenient check for exhaust gas leakage into cooling system is provided by a commercially avail- able Block Leak Check tool. Follow manufacturers instructions when using this product.
COMBUSTION LEAKAGE TEST—WITHOUT PRESSURE TESTER
DO NOT WASTE reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
DR COOLING (Continued)
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.
coolant
Drain sufficient
to allow thermostat removal. (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL). Remove accessory drive belt (Refer to 7 - COOLING/ACCES- SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of the top of the thermostat housing.
COOLING
7 - 7
CAUTION: Avoid overheating. Do not operate engine for an excessive period of time. Open drain- cock 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 bub- bles do not appear, internal combustion gas leakage is not present.
DIAGNOSIS AND TESTING - COOLING SYSTEM DIESEL ENGINE
COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE
CONDITION
POSSIBLE CAUSES
CORRECTION
TEMPERATURE GAUGE READS LOWNOTE: Information on dash cluster is displayed based on broadcast data from ECM. DTC will be set for engine sensor circuit concern.
1. Vehicle is equipped with a heavy duty cooling system. 2. Thermostat stuck open 3. Coolant level low.
4. Temperature gauge not functioning correctly.
1. None. System operating normally.
2. Inspect and test thermostat. 3. Fill cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) 4. Check cluster (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING)
COOLING
7 - 8
COOLING (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
TEMPERATURE GAUGE READS HIGH. COOLANT MAY OR MAY NOT BE LEAKING FROM SYSTEMNOTE: Information on dash cluster is displayed based on broadcast data from ECM. DTC will be set for engine sensor circuit concern.
1. Vehicle overloaded, high ambient (outside) temperatures with A/C turned on, stop and go driving or prolonged operation at idle speeds. 2. Temperature gauge not functioning correctly.
3. Air trapped in cooling system
4. Radiator cap faulty. 5. Plugged A/C or radiator cooling fins. 6. Coolant mixture incorrect.
7. Thermostat stuck shut.
8. Bug screen or winter front being used. 9. Electronically controlled viscous fan drive not operating properly.
10. Cylinder head gasket leaking.
11. Heater core leaking. 12. Cooling system hoses leaking.
13. Brakes dragging.
14. Accessory drive belt. 15. Water Pump.
1. Temporary condition, repair not required. Notify customer of vehicle operation instructions located in Owners Manual. 2. Check cluster (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING) 3. Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE) and refill (Refer to 7
- COOLING - STANDARD PROCEDURE) 4. Replace radiator cap. 5. Clean all debris away from A/C and radiator cooling fins. 6. Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE) refill with correct mixture (Refer to 7 - COOLING - STANDARD PROCEDURE). 7. Inspect and test thermostat. Replace thermostat if necessary. 8. Remove bug screen or winter front. 9. Check viscous fan (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING) 10. Check for leaking head gaskets (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). 11. Replace heater core. 12. Tighten clamps or Replace hoses. 13. Check brakes. (Refer to 5 - BRAKES/HYDRAULIC/ MECHANICAL - DIAGNOSIS AND TESTING) 14. Inspect. Replace as necessary. 15. Inspect and replace as necessary.DR COOLING (Continued)
COOLING
7 - 9
CONDITION
POSSIBLE CAUSES
CORRECTION
TEMPERATURE GAUGE READING INCONSISTENT (ERRATIC, CYCLES OR FLUCTUATES)NOTE: Information on dash cluster is displayed based on broadcast data from ECM. DTC will be set for engine sensor circuit concern.
1. Heavy duty cooling system, extreme cold ambient (outside) temperature or heater blower motor in high position.
2. Temperature gauge or sensor defective.
3. Temporary heavy usage or load. 4. Air trapped in cooling system.
5. Water pump 6. Air leak on suction side of water pump.
1. None. System operating normally.
2. Check cluster or engine coolant temp sensor (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING) 3. None. Normal condition. 4. Fill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). 5. Replace water pump. 6. Check for leak. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING)
RADIATOR CAP LEAKING STEAM AND /OR COOLANT INTO RESERVOIR BOTTLE. (TEMPERATURE GAUGE MAY READ HIGH)
HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING.
NOISY FAN
1. Radiator cap defective.
1. Replace radiator cap.
2. Radiator neck surface damaged.
2. Replace radiator.
1. Vacuum created in cooling system on engine cool-down is not being relieved through coolant reservoir/overflow system.
1. Replace radiator cap, check vent hose between radiator and reservoir bottle for blockage also check reservoir bottle vent for blockage.
1. Fan blade(s) loose, damaged. 2. Electronically controlled viscous fan drive. 3. Fan blades striking surrounding objects. 4. Electronically controlled viscous fan drive bearing.
5. Electronically controlled viscous fan stuck on
6. Obstructed air flow through radiator.
1. Replace fan blade assembly. 2. None. Normal condition.
3. Locate contact point and repair as necessary. 4. Check viscous fan (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING) 5. Check viscous fan (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING) 6. Remove obstruction.
COOLING
7 - 10
COOLING (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
INADEQUATE AIR CONDITIONER PERFORMANCE (COOLING SYSTEM SUSPECTED)
1. Radiator and/or A/C condenser air flow obstructed.
2. Electronically controlled viscous fan drive not working.
3. Air seals around radiator damaged or missing.
INADEQUATE HEATER PERFORMANCE. GAUGE MAY OR MAY NOT READ LOW.
1. Heavy duty cooling system, and cooler ambient temperatures.
2. Obstruction in heater hoses.
HEAT ODOR
3. Electronically controlled viscous fan stuck on
4. Water pump damaged.
1. Damaged or missing drive line heat shields. 2. Electronically controlled viscous fan drive damaged.
1. Remove obstruction and/or clean.
2. Check fan drive. (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING) 3. Inspect air seals, repair or replace as necessary.
1. None. Normal condition.
2. Remove hoses, remove obstruction. Check fan drive. (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING) 4. Replace water pump.
1. Repair or replace damaged or missing heat shields. 2. Check thermal viscous fan drive. (Refer to 7 - COOLING/ENGINE/ FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)
DIAGNOSIS AND TESTING - PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com- plaint. Abnormal loads on the cooling system such as the following may be the cause: † PROLONGED IDLE † VERY HIGH AMBIENT TEMPERATURE † SLIGHT TAIL WIND AT IDLE † SLOW TRAFFIC † TRAFFIC JAMS † HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are: † Idle with A/C off when temperature gauge is at † Increasing engine speed for more air flow is rec-
end of normal range.
ommended.
TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per- formed on vehicle that may effect the cooling system. This may be:
† Engine adjustments (incorrect timing) † Slipping engine accessory drive belt(s) † Brakes (possibly dragging) † Changed parts. Incorrect water pump or pump rotating in wrong direction due to belt not correctly routed† Reconditioned radiator or cooling system refill- ing (possibly under filled or air trapped in system). † Service to electrically controlled viscous fan
clutch
NOTE: If investigation reveals none of the previous items as a cause for an engine overheating com- plaint, to COOLING SYSTEM DIAGNOSIS CHART BELOW.
refer
These charts are to be used as a quick-reference to COOLING SYSTEM DIAGNOSIS
only. Refer CHART
DR COOLING (Continued)
COOLING
7 - 11
COOLING SYSTEM DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSES
CORRECTION
TEMPERATURE GAUGE READS LOW
1. Has a Diagnostic Trouble Code (DTC) been set indicating a stuck open thermostat?
2. Is the temperature sending unit connected?
3. Is the temperature gauge operating OK?
4. Coolant level low in cold ambient temperatures accompanied with poor heater performance.
5. Improper operation of internal heater doors or heater controls.
1. (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION) for On-Board Diagnostics and DTC information. Replace thermostat if necessary. 2. Check the temperature sensor connector. (Refer to 8 - ELECTRICAL/ INSTRUMENT CLUSTER - SCHEMATIC - ELECTRICAL) Repair connector if necessary. 3. Check gauge operation. (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER/ ENGINE TEMPERATURE GAUGE - DESCRIPTION). Repair as necessary. 4. Check coolant level in the coolant reserve/overflow tank or degas bottle and the radiator. Inspect system for leaks. Repair leaks as necessary. Refer to the Coolant section of the manual text for WARNINGS and CAUTIONS associated with removing the radiator cap. 5. Inspect heater and repair as necessary. (Refer to 24 - HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING) for procedures.
COOLING
7 - 12
COOLING (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
TEMPERATURE GAUGE READS HIGH OR THE COOLANT WARNING LAMP ILLUMINATES. COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM THE COOLING SYSTEM
1. Trailer is being towed, a steep hill is being climbed, vehicle is operated in slow moving traffic, or engine is being idled with very high ambient (outside) temperatures and the air conditioning is on. Higher altitudes could aggravate these conditions.
2. Is the temperature gauge reading correctly?
3. Is the temperature warning illuminating unnecessarily?
4. Coolant low in coolant reserve/overflow tank and radiator? 5. Pressure cap not installed tightly. If cap is loose, boiling point of coolant will be lowered. Also refer to the following Step 6. 6. Poor seals at the radiator cap.
7. Coolant level low in radiator but not in coolant reserve/ overflow tank. This means the radiator is not drawing coolant from the coolant reserve/ overflow tank as the engine cools (5.9L).
8. Incorrect coolant concentration
9. Coolant not flowing through system
1. This may be a temporary condition and repair is not necessary. Turn off the air conditioning and attempt to drive the vehicle without any of the previous conditions. Observe the temperature gauge. The gauge should return to the normal range. If the gauge does not return to the normal range, determine the cause for overheating and repair. Refer to Possible Causes (2-18). 2. Check gauge. (Refer to 8 - ELECTRICAL/INSTRUMENT CLUSTER - SCHEMATIC - ELECTRICAL). Repair as necessary. 3. (Refer to 8 - ELECTRICAL/ INSTRUMENT CLUSTER - SCHEMATIC - ELECTRICAL). 4. Check for coolant leaks and repair as necessary. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). 5. Tighten cap
6. (a) Check condition of cap and cap seals. Refer to Radiator Cap. Replace cap if necessary. (b) Check condition of radiator filler neck. If neck is bent or damaged, replace radiator (5.9L) or degas bottle (3.7L, 4.7L). 7. (a) Check condition of radiator cap and cap seals. Refer to Radiator Cap in this Group. Replace cap if necessary. (b) Check condition of radiator filler neck. If neck is bent or damaged, replace radiator. (c) Check condition of the hose from the radiator to the coolant tank. It should fit tight at both ends without any kinks or tears. Replace hose if necessary. (d) Check coolant reserve/overflow tank and tanks hoses for blockage. Repair as necessary. 8. Check coolant. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). 9. Check for coolant flow at radiator filler neck with some coolant removed, engine warm and thermostat open. Coolant should be observed flowing through radiator. If flow is not observed, determine area of obstruction and repair as necessary.
DR COOLING (Continued)
COOLING
7 - 13
CONDITION
POSSIBLE CAUSES
CORRECTION
10. Radiator or A/C condenser fins are dirty or clogged.
11. Radiator core is corroded or plugged. 12. Fuel or ignition system problems.
13. Dragging brakes.
14. Bug screen or cardboard is being , reducing airflow. 15. Thermostat partially or completely shut.
16. Viscous fan drive not operating properly.
17. Cylinder head gasket leaking.
18. Heater core leaking.
10. Remove insects and debris. (Refer to 7 - COOLING - STANDARD PROCEDURE). 11. Have radiator re-cored or replaced.
12. Refer to 14 - Fuel System or 8 - Electrical for diagnosis and testing procedures. 13. Check and correct as necessary. (Refer to 5 - BRAKES - DIAGNOSIS AND TESTING) for correct procedures. 14. Remove bug screen or cardboard.
15. Check thermostat operation and replace as necessary. (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL) . 16. Check fan drive operation and replace as necessary. (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL). 17. Check for cylinder head gasket leaks. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). 18. Check heater core for leaks. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - DIAGNOSIS AND TESTING). Repair as necessary.
COOLING
7 - 14
COOLING (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
Temperature gauge reading is inconsistent (flucttuates, cycles or is erratic)
PRESSURE CAP IS BLOWING OFF STEAM AND/OR COOLANT TO COOLANT TANK. TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL BUT NOT HIGH. COOLANT LEVEL MAY BE HIGH IN COOLANT RESERVE/ OVERFLOW TANK
COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF. GAUGE READING HIGH OR HOT
1. During cold weather operation, with the heater blower in the high position, the gauge reading may drop slightly.
2. Temperature gauge or engine mounted gauge sensor defective or shorted. Also, corroded or loose wiring in this circuit. 3. Gauge reading rises when vehicle is brought to a stop after heavy use (engine still running) 4. Gauge reading high after re-starting a warmed up (hot) engine.
5. Coolant level low in radiator (air will build up in the cooling system causing the thermostat to open late). 6. Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing a thermostat to open late.
7. Water pump impeller loose on shaft.
8. Loose accessory drive belt. (water pump slipping)
9. Air leak on the suction side of the water pump allows air to build up in cooling system causing thermostat to open late.
1. Pressure relief valve in radiator cap is defective.
1. A normal condition. No correction necessary.
2. Check operation of gauge and repair if necessary. (Refer to 8 - ELECTRICAL/ INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). 3. A normal condition. No correction is necessary. Gauge should return to normal range after vehicle is driven. 4. A normal condition. No correction is necessary. The gauge should return to normal range after a few minutes of engine operation. 5. Check and correct coolant leaks. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING).
6. (a) Check for cylinder head gasket leaks. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). (b) Check for coolant in the engine oil. Inspect for white steam emitting from the exhaust system. Repair as necessary. 7. Check water pump and replace as necessary. (Refer to 7 - COOLING/ ENGINE/WATER PUMP - REMOVAL). 8. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - DIAGNOSIS AND TESTING). Check and correct as necessary. 9. Locate leak and repair as necessary.
1. Check condition of radiator cap and cap seals. (Refer to 7 - COOLING/ENGINE/ RADIATOR PRESSURE CAP - DIAGNOSIS AND TESTING). Replace cap as necessary.
1. Coolant leaks in radiator, cooling system hoses, water pump or engine.
1. Pressure test and repair as necessary. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING).
DR COOLING (Continued)
COOLING
7 - 15
CONDITION
POSSIBLE CAUSES
CORRECTION
1. Engine overheating.
1. Check reason for overheating and repair as necessary.
2. Freeze point of coolant not correct. Mixture is too rich or too lean.
2. Check coolant concentration. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION).
1. Vacuum created in cooling system on engine cool-down is not being relieved through coolant reserve/overflow system.
1. (a) Radiator cap relief valve stuck. (Refer to 7 - COOLING/ENGINE/ RADIATOR PRESSURE CAP - DIAGNOSIS AND TESTING). Replace if necessary
DETONATION OR PRE- IGNITION (NOT CAUSED BY IGNITION SYSTEM). GAUGE MAY OR MAY NOT BE READING HIGH
HOSE OR HOSES COLLAPSE WHILE ENGINE IS RUNNING
(b) Hose between coolant reserve/overflow tank and radiator is kinked. Repair as necessary. (c) Vent at coolant reserve/ overflow tank is plugged. Clean vent and repair as necessary.
NOISY VISCOUS FAN/DRIVE
1. Fan blades loose.
2. Fan blades striking a surrounding object. 3. Air obstructions at radiator or air conditioning condenser.
4. Thermal viscous fan drive has defective bearing.
5. A certain amount of fan noise may be evident on models equipped with a thermal viscous fan drive. Some of this noise is normal.
(d) Reserve/overflow tank is internally blocked or plugged. Check for blockage and repair as necessary.
1. Replace fan blade assembly. (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL) 2. Locate point of fan blade contact and repair as necessary. 3. Remove obstructions and/or clean debris or insects from radiator or A/C condenser. 4. Replace fan drive. Bearing is not serviceable. (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL). 5. (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DESCRIPTION) for an explanation of normal fan noise.COOLING
7 - 16
COOLING (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
INADEQUATE HEATER PERFORMANCE. THERMOSTAT FAILED IN OPEN POSITION
STEAM IS COMING FROM THE FRONT OF VEHICLE NEAR THE GRILL AREA WHEN WEATHER IS WET, ENGINE IS WARMED UP AND RUNNING, AND VEHICLE IS STATIONARY. TEMPERATURE GAUGE IS IN NORMAL RANGE
COOLANT COLOR
COOLANT LEVEL CHANGES IN COOLANT RESERVE/ OVERFLOW TANK. TEMPERATURE GAUGE IS IN NORMAL RANGE
1. (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION) for correct procedures and replace thermostat if necessary
2. (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). 3. Remove heater hoses at both ends and check for obstructions 4. Locate kinked area and repair as necessary 5. (Refer to 7 - COOLING/ENGINE/ WATER PUMP - REMOVAL). If a slipping belt is detected, (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - DIAGNOSIS AND TESTING). If heater core obstruction is detected, (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/HEATER CORE - REMOVAL).
1. Occasional steam emitting from this area is normal. No repair is necessary.
1. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). Adjust coolant mixture as necessary.
1. A normal condition. No repair is necessary.
1. Has a Diagnostic trouble Code (DTC) been set?
2. Coolant level low
3. Obstructions in heater hose/fittings 4. Heater hose kinked
5. Water pump is not pumping water to/through the heater core. When the engine is fully warmed up, both heater hoses should be hot to the touch. If only one of the hoses is hot, the water pump may not be operating correctly or the heater core may be plugged. Accessory drive belt may be slipping causing poor 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.
