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COOLING SYSTEM

CONTENTS

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ACCESSORY DRI VE BELTS . . . . . . . . . . . . . . . . 19ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 21GENERAL INFORM ATION . . . . . . . . . . . . . . . . . . 1

SERVICE PROCEDURES . . . . . . . . . . . . . . . . . .. 8SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 22

GENERAL INFORMATION

COOLING SYSTEMTh e coolin g sy st e m con sist s of a n e n gin e coolin g

m od u le, p r essu r e ca p , coola n t d e a e r a t ion p r essu r e

bot t le , t h e r m ost a t , coola n t , a n d a w a t e r p u m p t o cir -culate the coolant. The engine cooling module consist

of a r a d i a t or, el ect r i c f a n m ot or s , s h r ou d , i n t er n a l

transmission oil cooler, hoses, clamps, air condition-

ing condenser, and a receiver drier.

When Engine is cold: Thermostat is closed, cooling

system has no flow through the radiator. The coolant

flows through t he engine heater core, deaerat ion pres-

sure bott le an d by-pass.

When E ngine is w arm : Thermostat is open, coolan t

f low s t h r o ug h t h e r a d ia t o r, h e a t e r cor e , d e a e r a t ion

pressure bott le an d by-pass.

The cooling syst ems primar y purpose is to ma inta in

engine temperature in a range that will provide satis-factory engine performance and emission levels under

all expected driving conditions. I t also provides hot

coolant for heater performance and cooling for auto-

m a t i c t r a n s m i ss ion oi l. I t d oes t h i s b y t r a n s f er r in g

heat from engine meta l to coolan t , moving this h eated

cool a n t t o t h e r a d i a t or, a n d t h e n t r a n s f er r in g t h i s

h e a t t o t h e a m bien t a ir.

Coola nt flow circuit for t he 3.3/3.5L engine coolan t

routings is shown in (Fig. 1).

Fig. 1 Cooling System Operation3.3/3.5L Engine

COOLING SYSTEM 7 - 1


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COOLING SYSTEM DIAGNOSIS

7 - 2 COOLING SYSTEM


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SERVICE PROCEDURES

INDEX

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Automatic Transmission Oil Cooler . . . . . . . . . . . . 18Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Coolant Deaeration Pressure Bottle . . . . . . . . . .. 14Cooling System Drain, Clean, Flush and Filling . . . 12Deaeration Pressure Bottle Pressure Cap . . . . . . . 14Dual Fan Module . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electric Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . 18Engine Thermostats . . . . . . . . . . . . . . . . . . . . . . . . 9Radiator Hoses and Clamps . . . . . . . . . . . . . . . . . 17Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Testing System for Leaks . . . . . . . . . . . . . . . . . . . 13Water Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

WATER PUMPSA q u ick t es t t o t e ll w h et h er or n ot t h e pu m p i s

w o rk in g i s t o s ee i f t h e h ea t e r w a r m s p rop er l y. A

d e fe ct ive p u m p w ill n ot be a ble t o cir cu la t e h e a t e d

coolant through t he long heater hose.

The water pump on all models can be replaced

without discharging the air conditioning sys-

tem.

WATER PUMP3.3L ENGINE

Th e p u mp h a s a d ie c a s t a l um in u m b od y a n d a

st a m p e d st e el im pe ller. I t bolt s d ir ect ly t o t h e ch a in

case cover (Fig. 1), using an O-ring for sealing. I t is

driven by th e back surfa ce of the P oly-V Drive B elt .

REMOVAL

WARNING: DO NOT REMOVE PRESSURE CAP WITH

THE SYSTEM HOT AND UNDER PRESSURE BE-

CAUSE SERIOUS BURNS FROM COOLANT CAN

OCCUR.

(1) D r a in C o olin g S y st e m . Re fe r t o D r a in in g C o ol-

ing System in this group.

(2) Remove P oly V D rive Belt .

(3) Remove right front lower fender shield.

(4) Remove pump pulley bolts and remove pulley.

(5) Rem ove p u m p m ou n t in g scr e w s (F ig . 1). Re -

move pump.

(6) Remove a nd discard O-ring seal.

(7) C lea n O -r in g g r oove a n d O -r in g su r f a ce s on

pump a nd chain case cover. Take care not to scrat ch

or gouge sealing surface.

INSPECTIONRe pla ce t h e w a t e r p u m p i f i t h a s a n y o f t h e f o llow -

ing defects.

(1) Da ma ge or cra cks on th e pump body.

(2) Coolant leaks; if the seal is leaking, evident by

traces of coolant leaks from vent hole.

(3) Loose or rough turn ing bearing.

(4) Impeller rubs either the pump body or oil pump

housing.

INSTALLATION

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

(1) Install new O-ring in O-ring groove (Fig. 2).

(2) Ins ta ll pump to cha in cas e cover. Torque screws

to 12 N m (105 in. lbs.).

(3) Ro t a t e p u m p by h a n d t o ch e ck f o r f r e e d o m o f

movement.

(4) P o s it i on p ul le y on p um p . I n s t a l l s cr ew s a n d

torque to 30 N m (250 in. lbs.).

Fig. 1 Water Pump3.3L Engine

Fig. 2 Water Pump Body



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(5) Inst all dr ive belt . S ee Accessory D rive B elts th is

group.

(6) Install r ight front lower fender shield.

(7) Re fi l l C o olin g S y st e m . S e e Re fi ll in g C o olin g

System in this section.

WATER PUMP3.5L ENGINE

The 3.5L pump bolts directly to the engine block,using a O-ring gasket for pump to block sealing (Fig.

4). The pump is serviced as a unit.

REMOVAL




OCCUR.

(1) Dra in cooling syst em. Refer t o Dra ining Cooling

System in this group.

(2) T h e w a t e r p u m p is d r ive n by t h e t im in g be lt .

Re fe r t o Tim in g B e lt S y st e m S e r vice in G r ou p 9 En -

gine, for component removal to provide access to wa-

ter pump.

(3) Remove mounting bolts.

(4) Remove pump body from engine (Fig. 3).

INSPECTION

Re pla ce t h e w a t e r p u m p i f i t h a s a n y o f t h e f o llow -ing defects.

(1) Da ma ge or cracks on t he pump body.

(2) C o o la n t le a k s, i f t h e sh a f t se a l is le a k in g , e vi-

dent by traces of coolant leaks from behind pulley.

(3) Impeller rubs inside of pump.

(4) Excessively loose or rough turning bearing.

INSTALLATION

(1) Clean all O-ring surfa ces on pump a nd block.

(2) Install new O-ring on water pump (Fig. 4). Wet

the O-ring with water to facilitate assembly.

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

(3) I n s t a l l p um p t o h ou s in g m ou n t in g b ol t s a n d

tighten to 12 N m (105 in. lbs.).(4) R ef er t o Ti m in g S y s t em i n E n g i ne S e ct i on ,

G r o u p 9 f or t im in g be lt in st a l la t ion p r oced u r e a n d

reassemble engine.

(5) Fill cooling system. Refer to Refilling Cooling

S y st e m .

ENGINE THERM OSTATSTh e e n g in e t h e r m ost a t is lo ca t e d in a w a t e r bo x,

f or m e d in t h e f r on t of t h e in t a k e m a n if old (F ig . 5).

T h is t h e r m o st a t h a s a n a ir ble e d lo ca t e d in t h e t h e r -

m o st a t f la n g e.

DESCRIPTION AND OPERATIONTh e en g in e cool in g t h e rm os t a t s a r e w a x p el le t

driven, reverse poppet choke type. They are designed

to provide the fast est w arm up possible by preventing

l ea k a g e t h r o ug h t h em a n d t o g u a r a n t e e a m i n im u m

engine operating temperature of 90 C (195F). They

a l s o a u t om a t i ca l l y r ea c h w i d e o pe n s o t h e y d o n o t

r es t r ict f low t o t h e r a d i a t or a s t e m pe ra t u r e of t h e

coolant r ises in hot weather to around 104C (220F).

Above 90C (195F) t he coolant tempera ture is con-

trolled by the radiator, fan, and ambient temperature,

n ot t h e t h e r m ost a t .

OPERATION AND TESTINGTh e t h er m os t a t i s op er a t e d b y a w a x f il le d c on -

t a in er (p elle t ) w h ich is se a led so t h a t w h e n h e a t e d t o

a p re de t er m in ed t e mp er a t u r e. Th e w a x e xp a n d s

e nou g h t o ov er com e t h e cl os in g s pr i ng a n d w a t e r

pump pressure, which forces the valve to open. Cool-

a n t lea k a g e in t o t h e p e llet w il l ca u se a t h e r m ost a t t o

fail open. Do not at tempt to free up a thermostat with

a screwdriver.

The open too soon type failure mode is included in

the on-boar d diagnosis. The check engine light will

n ot b e l it b y a n op en t oo s o on con d it i on . I f i t h a s

Fig. 3 Water Pump3.5L Engine

Fig. 4 Water Pump Body3.5L Engine



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f a i le d op en , cod e 17 w i ll b e s e t . D o n ot ch a n g e a

thermostat for lack of heat by gauge or heater perfor-

m a n ce , u n le ss cod e 17 is p r ese n t , se e d ia g n o sis f or

other probable causes. Fa iling shut is the norma l long

t e rm m od e of f a i lu r e, a n d n or m a l ly, on l y on h i gh

mileage vehicles. The t empera ture gauge will indicat e

this, R efer t o diagnosis in t his section.

REMOVAL




OCCUR.

(1) D r a in coolin g sy st e m d ow n t o t h e r m ost a t level

or below.

(2) Re m ove t h e r m ost a t h ou sin g bolt s a n d h ou sin g

(Fig. 5).

(3) Rem ove t h e r m ost a t , d isca r d g a sk et a n d cle a n

both gasket sealing surfaces.

INSTALLATION

(1) I n st a l l t h e r m ost a t in t o r e ce ss p r ovid ed in t h e

intake manifold (Fig. 5).

(2) P l a ce a n ew g a s k et (d i pp ed i n w a t e r) o n t h e

water box surface, center thermostat into opening in

the intake manifold.

(3) P la ce h ou sin g over g a sk e t a n d t h e r m ost a t , B olt

h o u sin g t o in t a k e m a n if o ld , t o r q u e bo lt s t o 28 N m

(250 in . lbs.) 3.3L e n g in e a n d 28 N m (250 in. lbs.)

3.5L engine.

(4) Refill cooling system (see Refilling System).

COOLANTThe cooling system is designed around the coolant .

Th e coola n t m u st a cce pt h e a t f r om e n g in e m e t a l , in

the cylinder head area near the exhaust valves. Then

ca r r y t h i s h ea t t o t h e r a d i a t or w h e r e t h e t u b e/f in

heat er core an d plat e/fin ra diat or can give it up to the

air .

WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOLBASE COOLANT AND IS HARMFUL IF SWALLOWEDOR INHALED. IF SWALLOWED, DRINK TWO

GLASSES OF WATER AND INDUCE VOMITING. IFINHALED, MOVE TO FRESH AIR AREA. SEEK MEDI-CAL ATTENTION IMMEDIATELY. DO NOT STORE INOPEN OR UNMARKED CONTAINERS. WASH SKIN

AND CLOTHING THOROUGHLY AFTER COMING INCONTACT WITH ETHYLENE GLYCOL. KEEP OUT OFREACH OF CHILDREN.

DISPOSE OF GLYCOL BASE COOLANT PROP-

ERLY, CONTACT YOUR DEALER OR GOVERNMENTAGENCY FOR LOCATION OF COLLECTION CENTERIN YOUR AREA.

DO NOT OPEN A COOLING SYSTEM WHEN THE

ENGINE IS AT OPERATING TEMPERATURE OR HOTUNDER PRESSURE, PERSONAL INJURY CAN RE-SULT.

AVOID RADIATOR COOLING FAN WHEN ENGINE

COMPARTMENT RELATED SERVICE IS PER-FORMED, PERSONAL INJURY CAN RESULT.

PERFORMANCE

P e r for m a n ce is m e a su r a ble. F o r h e a t t r a n sf e r p u r ew a t e r a b s or b s 1 b t u p er m i nu t e f or ea c h d eg r ee of

t e m pe r a t u r e r ise f or e a ch p ou n d of w a t e r. Th is f or -

m u la is a l t e re d w h e n n e ce ssa r y a d d it ives t o con t r o l

boiling, freezing, a nd corrosion are added as follows:

P u r e Wa t e r (1 b t u ) b oi ls a t 100 C (212 F ) a n d

freezes a t 0C (32 F).

100 Percent Glycol (.7 btu) can cause a hot engine

a n d d et on a t i on a n d w i ll r a i se t h e f reez e poi nt t o

-22 C (-8 F).

50/50 G lycol a nd Distilled Wat er (.82 btu) is the

r ecom m en d ed com b in a t i on t h a t p rov id es a f r eez e

point of -37 C(-35 F).The ra diat or, w at er pump, en-

g in e w a t e r ja ck et , r a d ia t o r p r essu r e ca p , t h e r m ost a t ,

t e m pe r a t u r e g a u g e , coola n t se n sor a n d h e a t e r a r e a l l

des ign ed f or 50/50 gly col.

Where required, a 56 percent glycol and 44 percent

w a t e r m i xt u r e w i ll p rov id e a f r ee ze p oi n t of -59 C

(-50 F).

CAUTION: Richer mixtures cannot be measured withfield equipment and can lead to problems associ-

ated with 100 percent glycol.

Fig. 5 Thermostat, Housing 3.3/3.5L Engines



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SELECTION AND ADDITIVES

Th e u se of a lu m in u m cy lin d er h e a d s, in t a k e m a n i-

folds, and water pumps requires special corrosion pro-

t e ct ion . Mop a r An t if r ee ze or a n t i fr e ez e con t a in in g

Alugard 340-2, or their equivalent are recommended

for best engine cooling with out corrosion. To obta in

the maximum life of components in the engine cooling

sy st e m , m ixin g d ist i lled w a t e r w it h e t h y le n e-g ly colt y p e coola n t is r e com m e n d ed . U se (50 p e r ce n t d is-

tilled wa ter a nd 50 percent coolant for freezing pro-

tection to -35C (-30F) or 40 percent dist illed water

an d 60 percent coolan t where freezing protection t o

-50 C (-60 F) is required. If the coolant looses color or

becomes contaminated, drain, f lush, and replace with

fresh properly mixed solution.

SERVICE

Coolant should be changed the first t ime at 80,000

km (52,000 m iles) or three years, whichever occurs

first . Subsequent coolant changes should occur every

t w o y e a r s or 45,000 k m (30,000 m iles) w h ich eve rcomes first.

ROUTINE LEVEL CHECK

Do not remove deaeration pressure bottle capfor r outine coolant level inspections.

The coolan t deaerat ion pressure bott le provides a

quick visual m ethod for determining the coolan t level

without removing the pressure cap. With the engine

cold the level of the coolant in the coolant deaeration

pressure bott le (Fig. 6) should be w ithin 12 mm (1/2

in.) of cold fill level mark.

ADDING ADDITIONAL COOLANT

WARNING: DO NOT OPEN COOLING SYSTEMWHEN HOT AND UNDER PRESSURE BECAUSEPERSONAL INJURY AND SERIOUS BURNS FROMCOOLANT CAN OCCUR. ALLOW ENGINE TO COOL

BEFORE SERVICING COOLING SYSTEM.

(1) Try squeezing the upper radia tor h ose t o deter-

mine if the system is st ill pressurized. Continue only

if y o u a r e a ble t o sq u e e z e t h e h o se e a si ly ; o t h e r w ise

wa it for the system t o cool.

(2) Place a shop towel over the pressure cap on the

coola n t d e a e ra t ion p r essu r e bot t le t u r n t o t h e f ir ststop. Wait to see if a ny pressure is released. When no

p r essu r e is r e lea se d , p r ess d o w n on t h e ca p a n d t u r n

fully counter-clockwise.

WARNING: WHEN INSTALLING DRAIN HOSE TO AIRBLEED VALVE ON THERMOSTAT HOUSING, ROUTE

HOSE AWAY FROM ACCESSORY DRIVE BELT, AC-CESSORY DRIVE PULLEYS, AND ELECTRIC COOL-ING FAN MOTORS.

(3) Attach one end of a 6.35 mm (.250 in.) ID clear

hose that is approximately 1219 mm (48 in.) long, to

t h e b le ed v a l ve i n t h e t h er m os t a t . R ou t e t h e h os e

away from the accessory drive belt , drive pulleys and

electric cooling fa n. P lace the other end of hose into a

clean conta iner. The hose w ill prevent coolan t from

contacting the accessory drive belt when bleeding the

system during t he refilling opera tion.

(4) Open bleed valve.

(5) Slowly fill coolant pressure bottle (Fig. 6) until ast e a d y st r e a m of coola n t f low s f r om h ose a t t a ch e d t o

the bleed va lve.

(6) Gently squeeze upper radiator hose until all air

is removed from system.

(7) Close bleed va lve a nd cont inue filling to 1/2 inch

below ba se of f i ller n e ck of t h e coola n t d e a er a t ion

pressure bottle. This will be a level above the cold fill

mark on the bott le.

(8) Inst all cap on coolan t pressure bott le.

(9) Remove hose from bleed valve.

Cooling system will remove trapped air from

itself during normal driving. It is recommendedthat lower engine speeds be used to allow the

cooling system to purge itself of any trapped air

for about 20 to 30 minutes before extended op-

eration at high engine speeds (above 4000

RPM).

LOW COOLANT LEVEL

Low coolant level in a cross flow radiator will equal-

i ze i n b ot h t a n k s w i t h e ng in e of f. Wi t h e ng in e a trunning and at operating temperature, the high pres-

su re i n l e t t a n k ru n s f u l l a n d t h e l o w p re ssu re o u t l e t

t a n k d rop s. I f t h i s l e v el d rop s b e low t h e t op o f t h e

t r a n s m is s ion oi l cool er, a i r w i l l b e d r a w n i nt o t h e

wa t e r p u m p:

Tra nsmiss ion oil will become hott er.

High reading shown on the temperature gauge.

Ai r i n t h e cool a n t w i ll a l so ca u s e l os s of f low

through the heater core.

Ex h a u st g a s le a k s in t o t h e co o la n t ca n a lso ca u se

the sa me problems.

Fig. 6 Coolant Deaeration Pressure Bottle



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DEAERATION

Air is r e m oved f r o m t h e sy st e m a s i t g a t h e r s in t h e

coolant deaerat ion pressure bott le a nd is released int o

the atmosphere through the pressure valve located in

the pressure cap when pressure reaches 97-124 kPa

(16-18 psi.). The air is replaced with coolant from the

coolant deaerat ion bott le.

COOLING SYSTEM DRAIN, CLEAN, FLUSH ANDFILLING

D r a i n, f lu sh , a n d f il l t h e cool in g s y st em a t t h e

m i le a g e o r t i m e i n t er v a l s s pe ci fi ed i n t h e M a i n t e-

n a n ce S ch e du le in t h is G r ou p . I f t h e so lut ion is d ir t y

or r u st y or con t a in s a con sid er a ble a m ou n t of sed i-

ment, clean and flush with a clean water. Care should

be ta ken in disposing of th e used engine coolan t from

your vehicle. Check governmenta l r egulat ions for dis-

posal of used engine coolant.

DRAINING

WARNING: DO NOT REMOVE THE CYLINDER

BLOCK DRAIN PLUGS OR COOLANT DEAERATION

PRESSURE BOTTLE CAP, OR OPEN THE RADIATOR

DRAINCOCK, WHEN THE SYSTEM IS HOT AND UN-

DER PRESSURE BECAUSE SERIOUS BURNS FROM

THE COOLANT CAN OCCUR.

Wh e n se rvicin g t h e coolin g sy st e m , i t is e sse n t ia l

t h a t coola n t d oe s n o t d r ip o n t o t h e a cce ssor y d r ive

belt an d/or pulleys. S hield the belt with shop towels

before working on the cooling system. If coolant con-

tacts the belt or pulley, f lush both with clean water.(1) Open radiator dra in located at th e lower r igh t s ide

of radiator (Fig. 1). Drain takes place through the lower

isolator. Do Not Use pliers to open draincock.(2) Re m ove coola n t p r essu r e bot t le ca p a n d op en

the thermostat bleed valve.

(3) Remove the cylinder block drain plug(s) located

behind each exhaust manifold.

CAUTION: The cooling system normally operates at

97-140 kPa (14-18 psi) pressure. Exceeding thispressure may damage the radiator or hoses.

CLEANING

Dra in coolin g system (see: Draining Cooling Sys-tem ) and refill with clean distilled water (see: RefillingCooling System ). R u n e ng in e w i t h r a d i a t or ca p i n -stal led u n ti l u p p er radiator h ose is warm. Stop en gin e

a n d d r a i n w a t e r f r om s y st e m . I f w a t e r i s d i rt y, f i ll , r u n

an d drain system again u n ti l water ru n s clear.

REVERSE FLUSHING

Reverse flushing of the cooling system is the forcing

o f w a t e r t h r o u g h t h e co o lin g sy st e m , u sin g a ir p r e s-

sure in a direction opposite to th at of the normal flow

of water. This is only necessary with dirty systems or

in case of partia lly plugged syst ems.

RADIATOR

D r a i n cool in g s y s t em a n d r em ov e r a d i a t or h os es

f r om e n gin e. I n st a l l su it a ble f lu sh in g g u n in r a d ia t o r

lower hose. Fill radiator with clean water and turn on

a ir in sh o r t bla st s .

CAUTION: Internal radiator pressure must not ex-ceed 138 kPa (20 psi) as damage to radiator mayresult. Continue this procedure until water runsclear.

ENGINE

D r a in r a d ia t o r (se e : Draining Cooling System )and remove hoses from ra diat or. Remove engine ther-

m ost a t a n d r e in st a l l t h e r m ost a t h ou sin g. I n st a l l su it -

a ble f lu sh in g g u n t o t h e r m ost a t h ou sin g h o se. Tu r n

o n w a t e r , a n d w h e n e n g in e is f i l le d , t u r n o n a ir , bu t

no higher tha n 138 kP a (20 psi) in short bla sts. Allow

en g in e t o f il l b et w e en b la s t s of a i r. C on t i n ue t h i s

p r o ce d u r e u n t i l w a t e r r u n s cle a n . I n st a l l t h e r m o st a t

using a new housing gasket. Fill cooling system (See

Refilling Cooling System ).

FILLING

U s e M op a r Al l S e a s on C ool a n t , or a n e q ui va l en t

coolant containing ALUGARD 340-2 or its equivalent

is necessary for best engine cooling without corrosion.

Re fe r t o S e lect ion a n d Ad d it ive s in t h is se ct ion f or

appropriat e coolan t mixture to use.

(1) Close radiator drain. Hand t ighten only.

(2) Inst all t he cylinder block drain plugs.

WARNING: WHEN INSTALLING DRAIN HOSE TO AIRBLEED VALVE ON THERMOSTAT HOUSING, ROUTE

HOSE AWAY FROM ACCESSORY DRIVE BELT, AC-CESSORY DRIVE PULLEYS, AND ELECTRIC COOL-ING FAN MOTORS.

Fig. 1 Radiator Draincock Location



13/22

(3) Attach one end of a 6.35 mm (.250 in.) ID clear

hose that is approximately 1219 mm (48 in.) long, to

t h e blee d va lve in t h e t h e r m ost a t (F ig . 3). Rou t e t h e

hose aw ay from the a ccessory drive belt , drive pulleys

a n d e le ct r ic co o lin g f a n . Pla ce t h e o t h e r e n d o f h o se

into a clean container. The hose will prevent coolant

from contacting the accessory drive belt when bleed-

ing th e system dur ing the r efilling operat ion.

(4) Open bleed valve.

(5) Slowly fill coolant pressure bottle (Fig. 2) until a

st e a d y st r e a m o f co o la n t f lo w s f r o m h o se a t t a ch e d t o

the bleed va lve.

(6) Gently squeeze upper radiator hose until all air

is removed from system.

(7) Close bleed valve a nd continue filling to th e top

of the coolant deaeration pressure bottle (Fig. 3).(8) Inst all ca p on coolan t pressure bott le.

(9) Remove hose from bleed valve.

TESTING SYSTEM FOR LEAKSWith engine not running, wipe the deaeration filler

neck sealing seat clean.

At t a c h a r a d i a t or p res s ur e t e st e r t o t h e cool a n t

deaeration bott le, as shown in (Fig. 4) and apply 104

k P a (15 p si ) p r es s ur e. I f t h e p res s ur e d r op s m or e

than 2 psi in 2 minutes inspect all points for external

leaks.

Al l h os es , r a d i a t or a n d h ea t e r, s h ou ld b e m ov ed

while at 15 psi since some leaks occur while driving

due to engine rock, etc.

I f t h e re a r e n o e x t er n a l l ea k s a f t e r t h e g a u g e d ia l

s h ow s a d r op i n p re ss u r e, d et a c h t h e t e st e r. S t a r t

e n g in e a n d r u n t h e e n g in e t o n o r m a l o p e r a t in g t e m -

p e r a t u r e in o r d e r t o o p e n t h e t h e r m o st a t a n d a l lo w

t h e cool a n t t o e xp a n d . R e -a t t a ch t h e t e st e r. I f t h e

needle on the dial f luctua tes it indicat es a combustion

lea k , u su a lly a h e a d g a sk et lea k .

WARNING: WITH TOOL IN PLACE PRESSUREBUILDS UP FAST. ANY EXCESSIVE AMOUNT OF

PRESSURE BUILT UP BY CONTINUOUS ENGINE

OPERATION MUST BE RELEASED TO A SAFE

PRESSURE POINT. NEVER PERMIT PRESSURE TO

EXCEED 138 KPA (20 PSI).

If t he needle on the dia l does not fluctuat e, race the

engine a few t imes. If an abnormal amount of coolant

or steam is emitted from the tail pipe, it may indicate

a faulty head gasket, cra cked engine block or cylinder

h e a d .

Th er e m a y b e i n t e rn a l l ea k s w h i ch ca n b e d e t er -

mined by removing t he oil dip-stick. If wa ter globules

a p pe a r i n t er m ix ed w i t h t h e oi l i t w i ll i n di ca t e a n

i n t er n a l l ea k i n t h e e n gi n e. I f t h er e i s a n i n t er n a l

leak, the engine must be disassembled for r epair .

Fig. 2 Filling Cooling System

Fig. 3 Bleeding Cooling System While Filling With

Coolant

Fig. 4 Pressure Testing Cooling System



14/22

COOLANT DEAERATION PRESSURE BOTTLEThis system works in conjunction with the coolant

d e a e r a t io n p r e ssu r e bo t t le p r e ssu r e ca p t o k e e p t h e

coola n t f r ee o f t r a p p ed a ir . I t p r ovid es a volu m e f or

expansion and contraction and provides a convenient

a n d sa f e m e t h od f or ch e ck in g coola n t leve l a n d a d -

justing level a t at mospheric pressure. I t also provides

some reserve coolan t to cover minor leaks an d evapo-ration or boiling losses (Fig. 5).

Re fe r t o C o ola n t L e ve l C h e ck S e r vice , D e a e r a t ion

an d P ressure Cap sections for opera tion an d service.

DEAERATION PRESSURE BOTTLE PRESSURE CAPD e a e r a t io n bo t t le is e q u ip p e d w it h a p r e ssu r e ca p

which releases pressure at some point within a range

of 117 kP a 7 kP a (17 psi 1 ps i)(Fig . 6).Th e s y st em w i ll oper a t e a t h ig her t h a n a t m o-

s p h er i c p r es s u r e w h i ch r ai s e s t h e cool an t b oi li n g

point thus allowing increased radiator cooling capac-

ity.

There is a spring-loaded vent valve in the center of

t h e ca p t h a t a l low s t h e s ys t em t o p res su r iz e a n d

d e pr e ssu r ize w it h ou t cr ea t in g a va cu u m . I f va lve is

stuck open, coolant will escape to the overflow hose.

Th e r e is a lso a g a sk e t in t h e ca p t o se a l t o t h e t o p o f

the filler neck.

DEAERATION PRESSURE BOTTLE CAP TO

SEAL CHECKThe pressure cap upper gasket (seal) pressure relief

can be checked by removing cap (Fig. 7). Attach the

Ra d ia t or P r e ssu r e Tool t o t h e ca p a n d p u m p a ir in t o

t h e ca p . P r e ssu r e ca p u p p er g a sk e t sh o u ld r e lieve a t

124 kPa (18 psi) and hold pressure at 110 kPa (16 psi)

minimum.

WARNING: THE WARNING WORDS DO NOT OPENHOT ON THE DEAERATION PRESSURE BOTTLE

CAP IS A SAFETY PRECAUTION. WHEN HOT, PRES-

SURE BUILDS UP IN COOLING SYSTEM. TO PRE-

VENT SCALDING OR INJURY, THE DEAERATION

PRESSURE BOTTLE CAP SHOULD NOT BE RE-

MOVED WHILE THE SYSTEM IS HOT AND/OR UN-

DER PRESSURE.

There is no need to remove the pressure cap at anyt im e except for the following purposes:

(1) Checking a nd adjust an tifreeze freeze point .

(2) Refilling system with new coolant .

(3) Conducting service procedures.

(4) Checking for vacuum leaks.

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,

WAIT 15 MINUTES BEFORE REMOVING CAP. THEN

PLACE A SHOP TOWEL OVER THE CAP AND WITH-

OUT PUSHING DOWN ROTATE IT COUNTER-

CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS

TO ESCAPE THROUGH THE OVERFLOW TUBE ANDWHEN THE SYSTEM STOPS PUSHING OUT COOL-

ANT AND STEAM AND PRESSURE DROPS, RE-

MOVE THE CAP COMPLETELY. SQUEEZING THE

RADIATOR INLET HOSE WITH A SHOP TOWEL (TO

CHECK PRESSURE) BEFORE AND AFTER TURNING

TO THE FIRST STOP IS RECOMMENDED.

PRESSURE TESTING DEAERATION PRESSURE

BOTTLE CAP

D ip t h e p r e ssu r e ca p in w a t e r , cle a n a n y d e p o sit s

o f f t h e ve n t va lve o r i t s se a t a n d a p p ly ca p t o e n d o f

Ra diat or P ressure Tool. Working the plunger, bringt h e p r essu r e t o 104 k P a (15 psi) on t h e g a u g e. I f t h e

pressure cap fa ils to hold pressure of a t least 117 kP a

(17 psi) replace ca p. S eeCAUTION

If the pressure cap tests properly while positioned

on Ra diat or P ressure Tool (Fig. 7), but wil l not hold

p r e s s u r e o r v a c u u m w h e n p o s i t i o n e d o n t h e de a e r a -

t i on b ot t l e , i n s p ect t h e de a e r a t i on b ot t l e n e ck a n d

ca p g a s k et f or i r re gu la r i t ie s t h a t m a y p re ve n t t h e

cap from sealing properly.

Fig. 5 Coolant Deaeration Pressure Bottle

Fig. 6 Deaeration Pressure Cap Filler Neck



15/22

CAUTION: Radiator Pressure Tool is very sensitive

to small air leaks which will not cause cooling sys-tem problems. A pressure cap that does not have ahistory of coolant loss should not be replaced just

because it leaks slowly when tested with this tool.Add water to the tool. Turn tool upside down and

recheck pressure cap to confirm that cap is bad.

INSPECTION

H ol d t h e ca p i n h a n d , right side up (Fig. 6). Thevent va lve at the bottom of the cap sh ould not open. If

t h e r u bber g a sk et h a s sw o llen a n d p r even t s t h e va lve

from closing, replace the cap.

H o ld t h e cle a n e d ca p in h a n d upside down. I f a n yl ig ht ca n b e s een b et w e en v en t v a lv e a n d r ub ber

gasket, replace cap.

RADIATORSThe radiators are cross-flow types (horizontal tubes)

w it h d e sig n f ea t u r e s t h a t p r ovide g r e a t e r st r e n g t h a s

w e ll a s su f ficien t h e a t t r a n sf er ca p a bil it ie s t o k ee p

the engine satisfactorily cooled.

CAUTION: Plastic tanks, while stronger than brassare subject to damage by impact, such as wrenches.

RADIATOR DRAINCOCK SERVICE

REMOVAL

CAUTION: Use of pliers on draincock is not recom-

mended. Damage may occur to part. Draincockshould not be removed unless leakage observed.

(1) Tu r n t h e d r a in cock st e m cou n t e r clockw ise t o

u n scr ew t h e s t em . Wh en t h e s t em i s u n s cr ew e d t o

Fig. 7 Pressure Testing Radiator Cap

Fig. 8 Cooling Module

Fig. 9 Draincock Assembly



16/22

the end of its threa ds, turn back 1/8 turn an d pull the

stem (Fig. 9) from the radiator tank.

INSTALLATION

(1) Push the draincock assembly body into the tank

opening until it sna ps into place.

(2) Tig h t en t h e d r a in cock st e m by t u r n in g clock-

wise until it stops.

RADIATOR COOLANT FLOW CHECK

To d e t er m in e w h e t h e r coola n t is f low in g t h r o ug h

the cooling system, use the following procedure:

I f engine is cold, idle engine until normal operating

t e m pe r a t u r e is r e a ch e d . I f t h e u p p er r a d ia t or h ose is

hot, coolan t is circulat ing.

WARNING: DO NOT REMOVE COOLANT DEAERA-TION PRESSURE CAP WITH THE SYSTEM HOT ANDUNDER PRESSURE BECAUSE SERIOUS BURNS

FROM COOLANT CAN OCCUR.

RADIATOR

REMOVAL

(1) Disconnect negative ba ttery cable from ba ttery.

WARNING: DO NOT REMOVE THE CYLINDERBLOCK PLUG OR THE RADIATOR DRAINCOCK

WITH THE SYSTEM HOT AND UNDER PRESSUREBECAUSE SERIOUS BURNS FROM COOLANT CANOCCUR.

(2) Dra in cooling syst em. Refer t o Dra ining Cooling

S y s t em of t h i s s ect i on . F or N ew Yor k er a n d N ew

Yorker LH S models it will be necessar y t o remove the

sight shield and the right and left headlamp modules.

Refer to G roup 8L La mps for procedure.

(3) Ne w Yor k er an d Ne w Yor k er L H S m od el s i t

w ill be necessa ry to discha rge t he A/C syst em. Refer

to G roup 24 Heat ing a nd Air Conditioning for proce-

dure.

(4) Remove upper radiator crossmember (Fig. 10).

(5) Remove hose clamps and hoses from the radia-

tor.

(6) Disconnect aut omatic t ra nsmission hoses fromcooler and plug off.

(7) D iscon n e ct t h e f a n w ir in g con n e ct o r f r om t h e

RFI module (Fig. 11).

(8) Re m ove u p pe r r a d ia t o r m o un t in g scr e w s (F ig .

12). D i scon n ect t h e en gi ne b lock h ea t e r w i re i f

equipped.

CAUTION: Avoid bending the condenser inlet tube.Care should be taken not to damage radiator orcondenser cooling fins or water tubes during re-

moval.

(9) Remove the air conditioning condenser at tach-

i ng s cr ew s l oca t e d a t t h e f ron t of t h e r a d ia t or, i f

equipped. Lean condenser forward against bumper. I t

i s n ot n eces s a r y t o d i sch a r g e t h e a i r con d it i on i ng

system to remove radiator. On New Yorker and New

Yorker LHS models the condenser does not need to be

se p a r a t e d f r o m r a d ia t o r . Mo d u le m a y be r e m o ve d a s

an assembly.

(10) Ra d ia t o r ca n n ow be l i f t ed f r ee f r om e n gin e

compartment. C are should be taken not to dam-age radiator cooling fins or water tubes during

removal.

INSTALLATION

(1) Slide ra diat or and fan module or cooling module

d ow n in t o p osit ion , se a t t h e r a d ia t o r a ssem bly low e r

rubber isolators in the mount holes provided.

(2) Attach air conditioning condenser to radiator, if

equipped.

Torque mounting screws to 5 N m (45 in. lbs.). On

New Yorker a nd New Yorker LHS models connect

A/C lines to condenser. Refer to G roup 24 H eat ing

and Air Conditioning for procedures.

Fig. 10 Upper Radiator Crossmember

Fig. 11 Electric Fan Motor RFI Module



17/22

(3) Tor q u e r a d i a t or m ou n t in g s cr ew s t o 14 N m

(123 in . lbs.). C on n e ct e n gin e block h e a t e r w ir e i f

equipped.

(4) C on n e ct low e r r a d ia t o r h ose a n d cla m p . C o n -

n ect a u t om a t i c t r a n sm is si on h os es ; t or q ue h os e

clam ps t o 2.5 N m (22 in. lbs.).

(5) Connect fan motor electrical connection.

(6) Install upper radiator hose. Align hose so it does

not interfere with the accessory drive belt or engine.

Po sit io n h o se cla m p so i t w il l n o t in t e r f e r e w it h t h e

hood liner .

(7) Connect negative battery cable.

(8) Fill cooling system with coolant. Refer to Refill-ing Cooling Systems in t his group.

(9) O p er a t e e n g in e u n t i l i t r e a ch e s n o r m a l op er a t -

ing temperature. Check cooling system and automatic

transmission for correct fluid levels.

(10) On New Yorker and New Yorker LHS models,

I n st a l l r igh t a n d lef t h e a d la m p m od u les a n d t h e sig h t

shield t o the ra diator crossmember. Refer to G roup 8L

Lamps for procedure.

RADIATOR HOSES AND CLAMPSWARNING: IF VEHICLE HAS BEEN RUN RECENTLY,WAIT 15 MINUTES BEFORE WORKING ON VEHICLE.RELIEVE PRESSURE BY PLACING A SHOP TOWEL

OVER THE CAP AND WITHOUT PUSHING DOWNROTATE IT COUNTER-CLOCKWISE TO THE FIRSTSTOP. ALLOW FLUIDS TO ESCAPE THROUGH THEOVERFLOW TUBE AND WHEN THE SYSTEM STOPS

PUSHING OUT COOLANT AND STEAM AND PRES-SURE DROPS.

Th e h ose s a r e r e m oved by u sin g con st a n t t e n sion

clamp pliers to compress hose clamp.

A h a r d en ed , cr a c ked , s w ol le n or r es t r ict e d h os e

should be replaced. Do not damage radiator inlet and

outlet when loosening hoses.

Radiator hoses should be routed without any kinks

and indexed as designed. The use of molded hoses is

recommended.

S p r in g t y p e h os e c l a m ps a r e u s ed i n a l l a p pl ica -t ion s. I f r e pla cem e n t is n e ce ssa r y r e pla ce w it h t h e

original MOPAR equipment spring type clamp.

DUAL FAN MODULEAll models use electric motor driven fans. The fan

m o du les in clu d e a m ot o r su pp or t a n d sh r ou d . Th e

m od u le i s f a s t e n ed t o t h e r a d i a t or b y s cr ew s w i t h

U-nuts a nd retaining clips (Fig. 13).

Th e d u a l f a n m od u le i s a com b in a t i on of 2 f a n s

m o un t e d in a on e p iece sh r ou d w h ich op er a t e a t t w o

sp ee ds a n d a r e sim u lt a n e ou sly a ct iva t e d . Th e d u a l

fan system improves engine cooling a nd air condition-

in g p e r for m a n ce in h ot w e a t h e r a n d se ve r e d r ivin g

conditions, while reducing fan noise and power con-

s um pt i on . At t em pt s t o r ed uce h ig h t em per a t u re

g a u g e r e a d i ng b y i n cr ea s i n g en g in e s pe ed , a t t h e

sam e vehicle speed, can increase high t empera ture.

FAN SHROUD

Al l v eh i cl es h a v e f a n s h r ou d s t o i m pr ov e f a n a i r

flow efficiency. The shroud supports the electric fa n

m o t or a n d f a n .

REMOVAL

(1) Disconnect electric lead to the RFI module.(2) R e m ov e f a n m od u le t o r a d i a t or f a s t en er s a n d

retaining clips (Fig. 13).

(3) Remove a ssembly from ra diator.

FAN SERVICE

(1) To remove fan from motor s ha ft, bench support

t h e m o t o r a n d m o t o r s h a f t , w h i l e r e m o v i n g t h e f a n

r e t a in in g cl ip or n u t , so t h a t t h e sh a f t a n d m ot o r w il l

Fig. 12 Radiator ModuleAll Models

Fig. 13 Servicing Fan Module



18/22

not be damaged by excessive force. Surface or burr

removal may be required to remove fan from

motor shaft. (Fig. 14). Do not permit the fan blades

to t ouch th e bench.

(2) To insta ll fan on motor sh aft , slide the fan over

sh a f t . S u p por t m ot o r a n d sh a f t a s a bo ve w h ile in st a l l-

ing fan retaining clip or retaining nut.

FAN MOTOR SERVICE

(1) Remove the motor fasteners from support (Fig.

13). R emove motor fr om support.

(2) Rever se t h e a bo ve p r oced u r e f or I n st a l la t io n .

Torque the fa n motor fast eners to 3 N m (25 in. lbs.)

r i gh t f a n a n d 5 N m (45 in. lbs.) left fan.

INSTALLATION

(1) I n s t a l l a s s em b ly t o r a d i a t or. At t a c h r et a i n in g

clips and torque shroud to radiator fasteners to 5 N m

(45 in. lbs.).

(2) Connect fan motor lead. For wiring diagrams

of fan motor systems Refer to 8W Wiring Dia-

grams.

RADIATOR FAN CONTROL

F a n co n t r o l is a cco m p lish e d t w o w a y s. A p r e ssu r e

transducer on the compressor discharge line sends a

signal to the powertrain control module (PCM) which

will activate both fans if necessary. In addit ion to this

co n t r o l , t h e f a n is t u r n e d o n ba se d o n co o la n t t e m -p er a t u r e se n sor ou t p u t t o t h e P ow e r C o n t r ol Mod u le

( P C M ) . T h e P C M s w i t c h e s t h e f a n s o n t h r o u g h t h e

f a n r el a ys . R ef er t o Wi ri ng D i a gr a m s M a n ua l f or

circuit an d dia gnostics.

S w i t ch in g t h r ou gh t h e P o w er C on t r ol M od ul e

(P C M) p r o vid es f a n con t r o l f or t h e f ol low in g con d i-

tions.

Regardless of coolant temperature the fan will not

r u n d u r in g cr a n k in g u n t i l t h e e n g in e st a r t s .

Fa n w ill run a ccording t o the chart in (Fig. 15).

TEMPERATURE GAUGE INDICATION

At i dl e t h e t e m pe ra t u r e g a u g e w i l l r i se s low l y t o

about 5/8 ga uge tra vel. D uring n orma l driving opera-

t io n t h e f a n w il l co m e o n a n d t h e g a u g e w il l d r o p t oa bout 1/2 ga uge t ra vel.

ELECTRIC FAN MOTORRefer t o P ower Train Dia gnostic Manua l for proce-

dure.

ELECTRIC FAN MOTOR TEST

Refer t o P ower Train Dia gnostic Manua l for proce-

dure.

AUTOM ATIC TRANSMI SSION OIL COOLERTh e oi l cool er i s a n i n t er n a l oi l t o cool a n t t y p e

mounted in the radiator left tank (Fig. 16). Steel tubeand rubber oil lines feed the oil cooler and the auto-

m a t ic t r a n sm ission . U se on ly a p p r oved t r a n sm ission

oil cooler h ose. S in ce t h e se l in e s a r e m old ed , on ly

molded h oses are recommended. F lare the end of steel

tube to ensure sealing of the hose. Torque Oil Cooler

Hose Clamps to 2.5 N m (22 in. lbs.).

Fig. 14 Servicing Radiator Fans

Fig. 15 Radiator Fan Control Chart

Fig. 16 Transmission Oil Cooler



19/22

ACCESSORY DRIVE BELTS

INDEX

page page

3.3/3.5L Engine Accessory Drive Belt Service . . . . 19 General Information . . . . . . . . . . . . . . . . . . . . . . . 19

GENERAL INFORMATION

PROPER BELT TENSION

Sa tisfactory performa nce of t he belt d riven a ccesso-

ries depends on belt condition (Fig. 1) and proper belt

tension.

BELT TENSION GAUGE METHOD

U se belt tensioning Special Tool K it C-4162 for:

For conventional belts and Poly-V belts.

Ad ju st t h e belt t e n sion f or a New or Used belt

tension applications: Used Belt 534 N (120 lbs.)

New B elt 667 44 N (150 10 lbs.)

3.3/3.5L ENGINE ACCESSORY DRIVE BELTSERVICE

GENERATOR, POWER STEERING PUMP, AIR

CONDITIONING COMPRESSOR AND WATER

PUMP DRIVE BELT SERVICE

GENERATOR/POWER STEERING PUMP AND WATER PUMPBELT 3. 3L ENGINE

Th e P oly -V g en e r a t o r /p ow e r st e er in g a n d w a t e r

p u m p be lt is p r o vid e d by a n a d ju st in g scr e w o n t h e

g en er a t o r m ou n t in g b r a ck et (F i g. 3) t o m a i n t a i n

p r op er belt t e n sion . To r e m ove or in st a l l t h is belt ,

Release tension by loosening the generator mounting

bolt A a n d a d ju st in g bolt lockn u t B t h e n lo ose n a d -

justing bolt (Fig. 3). R everse procedure to insta ll a nd

tighten belt to specified tension.

Fig. 1 Drive Belt Inspection

ACCESSORY DRIVE BELTS DIAGNOSIS



20/22

GENERATOR/POWER STEERING PUM P BELT 3. 5L ENGINE

The P oly-V genera tor/power steering belt is pro-

vid ed by a d ju st a ble t e n sion e r p u lley loca t e d on t h e

t i m in g b el t cov er (F i g. 4) t o m a i n t a i n p rop er b el t

tension. To remove or ins ta ll th is belt, R elea se tens ion

by loosening the tensioner pulley nut and adjustment

bolt (Fig. 4). R everse procedure to inst all an d t ighten

belt to specified tension.

AIR CONDITIONING BELT 3.3/3.5L ENGINES

(1) Remove the genera tor/power steering pum p a nd

water pump drive belt to gain access to the air condi-

tioning drive belt .

(2) To remove and insta ll t he a ir conditioning com-

pressor drive belt , f irst loosen the tensioner pulley

l ock n u t , t h en t u r n t h e a d ju s t in g s cr ew t o r a i se orlower the t ensioner pulley assembly (Fig. 2 a nd 4).

To adjust the air conditioning drive belt,

loose n t h e t e n sion e r p u lley n u t (F ig . 4) a n d a d ju st

belt t e n sion by t ig h t e n in g a d ju st in g scr e w (F ig s. 2

a nd 4). Torque pulley nut to 54 N m (40 ft . lbs.) after

a d ju st m e n t .

Fig. 2 Accessory Drive 3.3L Engine

Fig. 3 Generator/Power Steering and Water PumpDrive Belt Adjustment 3.3L Engine

Fig. 4 Accessory Drive3.5L Engine



21/22

ENGINE BLOCK HEATER

DESCRIPTION AND OPERATIONOn all models an en gin e block h eater is available as

an optional accessory. The heater, operated by ordinary

house current (110 Volt A.C.) through a power cord and

connector behind the radiator grill. This provides easier

en g in e s t a r t in g a n d f a s t er w a r m -u p w h en v eh icl e i s

operated in areas h avin g extremely low temperatu res.

The heater is mounted in a core hole (in place of a core

hole plug) in the engine block, with the heating element

immersed in coolant (Fig. 10).

The power cord must be secured in its retainer

clips, and not positioned so it could contact link-

ages or exhaust manifolds and become damaged.

If unit does not opera te, trouble can be in either the

power cord or th e hea ter element. Test power cord for

contin uity wit h a 110-volt voltmeter or 110-volt t est

light ; test heater element continuity with an ohmme-

ter or 12-volt test light.

REMOVAL

(1) Drain coolant from radiator and cylinder block.

R ef er t o C o ol in g S y s t em D r a i n , C l ea n , F l us h a n d

Refill of this section for procedure.

(2) Detach power cord plug from heater.

(3) Loosen screw in center of heater. Remove heater

assembly.

INSTALLATION

(1) Thoroughly clean core hole and heater seat.

(2) Insert heater assembly with element loop posi-

tioned upward.(3) Wit h h e a t e r se a t e d , t ig h t e n ce n t er scr e w se -

curely to a ssure a posit ive seal.

(4) Fill cooling syst em w ith coolan t to t he proper level,

ven t air , an d in sp ect for leaks. Pressu rize system withRa dia tor P ressure Tool before looking for lea ks.

Fig. 5 Engine Block Heater



22/22

SPECIFICATIONS

TORQUE COOLING SYSTEM CAPACITY


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