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Cooling SRM 2006
Service Manual
110 pgs2.38 Mb0

Dodge Cooling SRM 2006 Service Manual

DR COOLING 7 - 1
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
GAS ENGINE ................................2
5.9L DIESEL .................................5
HOSE CLAMPS ..............................6
OPERATION
COOLING SYSTEM ..........................6
HOSE CLAMPS ..............................6
DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS (OBD) .............7
COOLING SYSTEM - TESTING FOR LEAKS ....7
COOLING SYSTEM DIESEL ENGINE ..........9
STANDARD PROCEDURE
COOLING SYSTEM CLEANING/REVERSE
FLUSHING.................................19
DRAINING COOLING SYSTEM - ALL GAS
ENGINES...................................20
REFILLING COOLING SYSTEM - ALL GAS
ENGINES...................................20
DRAINING COOLING SYSTEM - 5.9L
DIESEL ENGINE............................20
REFILLING COOLING SYSTEM - 5.9L
DIESEL ENGINE............................21
SPECIFICATIONS
SPECIAL TOOLS
ACCESSORY DRIVE ......................25
ENGINE ...............................39
TRANSMISSION .........................99
7 - 2 COOLING DR
COOLING
DESCRIPTION GAS ENGINE
Engine Cooling System Flow - 3.7L/4.7L
The 3.7L/4.7L engine cooling system consists of :
• LH Cylinder Head (1)
• Bleed (2)
• Thermostat location (3)
• RH Cylinder Head (4)
• RH Bank Cyl. Block (5)
• LH Bank Cyl. Block (6)
• Coolant Temp Sensor (7)
• From Heater Core (8)
• To Heater Core (9)
DR COOLING 7 - 3
The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temper­ature as quickly as possible. It also maintains normal operating temperature and prevents overheating.
5.7L Engine Coolant System Flow
The 5.7L engine cooling system consists of :
• LH Cylinder Head (1)
• To Radiator (2)
• From Radiator (3)
• To RH Cylinder Head (4)
The cooling system provides a means of heating the passenger compartment and cooling the automatic transmis­sion fluid (if equipped). The cooling system is pressurized and uses a centrifugal water pump to circulate coolant through the system. The coolant recovery/reserve system utilizes an ambient overflow bottle
7 - 4 COOLING DR
8.3L Cooling System
The 8.3L engine cooling system consists of :
• Thermostat Housing (1)
• Controlled Flow Thermostat (2)
• Water Pump (3)
• Radiator (4)
• Pressure Bottle To Water Pump (5)
• Pressure Bottle To Radiator (6)
• Coolant Recovery Bottle (7)
• Pressure Bottle To Coolant Recovery Bottle (8)
• Coolant Pressure Bottle With Pressure Cap (9)
• Heater Core (10)
• Control Valve (11)
An optional factory installed maximum duty cooling package is available on most models. This package will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient tem­peratures.
DR COOLING 7 - 5
5.9L DIESEL
Cooling System Circulation - 5.9L Diesel Engine
The diesel engine cooling system consists of :
7 - 6 COOLING DR
• Cross-flow radiator
• Belt driven water pump
• Cooling fan (attached to the electronic viscous fan drive)
• Belt driven Electronic viscous fan drive
• Engine mounted fan shroud
• Radiator pressure cap
• Vertically mounted thermostat
• Coolant reserve/recovery system
• Engine mounted Transmission oil cooler (Automatic Only)
• Radiator mounted fan shroud
• Coolant
HOSE CLAMPS
The cooling system utilizes spring type hose clamps. If a spring type clamp replacement is necessary, 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.
OPERATION COOLING SYSTEM
The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temper­ature as quickly as possible. It also maintains normal operating temperature and prevents overheating.
The cooling system also provides a source of hot water (coolant) for heating the passenger compartment and cool­ing the automatic transmission fluid (if equipped). The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system.
• When engine is cold the thermostat is closed. The cooling system has no flow through the radiator. The cool­ant flows through the engine, water pump, and heater.
• When engine is warm the thermostat is full open. The coolant flows through the engine, radiator, heater, and water pump.
All engines utilize an ambient overflow bottle for coolant recovery/reserve. An optional factory installed maximum duty cooling package is available on most models. This package will provide
additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient tem­peratures.
HOSE CLAMPS
The spring type hose clamp applies constant tension on a hose connection. To remove a spring type hose clamp, only use constant tension clamp pliers designed to compress the hose clamp.
DR COOLING 7 - 7
DIAGNOSIS AND TESTING ON-BOARD DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Engine Control Module (ECM) has been programmed to monitor certain cooling system components:
• If the engine has remained cool for too long a period, such as with a stuck open thermostat, a Diagnostic Trouble Code (DTC) can be set.
• 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 memory for eventual display to the service technician. (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC’s and to obtain cooling system data, (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION).
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 service information for operation of the DRBIIIT scan tool.
COOLING SYSTEM - TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the parts department that can be added to cooling system. 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 radiator upper hose is warm to the touch. Aim the commercially available black light tool at the components to be checked. If leaks are present, the black light will cause the additive to glow a bright green color.
The black light can be used in conjunction with a pressure tester to determine if any external leaks exist.
7 - 8 COOLING DR
PRESSURE TESTER METHOD
The engine should be at normal operating tempera­ture. Recheck the system cold if the cause of coolant loss is not located during the warm engine examina­tion.
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 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 necessary. 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 pressure. 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 INTERNAL LEAKAGE INSPECTION .
Drops Slowly: Indicates a small leak or seepage is occurring. Examine all of the connections for seepage or slight leakage with a flashlight. Inspect the radiator, hoses, gasket edges and heater. Seal the small leak holes with a Sealer Lubricant (or equivalent). Repair the leak holes and inspect the system again with pressure applied.
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 leakage.
WARNING: WITH RADIATOR PRESSURE TESTER TOOL INSTALLED ON RADIATOR, DO NOT ALLOW PRES­SURE TO EXCEED 145 kPa (21 PSI). PRESSURE WILL BUILD UP QUICKLY IF A COMBUSTION LEAK IS PRESENT. TO RELEASE PRESSURE, ROCK TESTER FROM SIDE TO SIDE. WHEN REMOVING TESTER, DO NOT TURN TESTER MORE THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
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 compression or combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic converter, do not short out cylinders to isolate compression leak.
DR COOLING 7 - 9
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 gasket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into cooling system is provided by a commercially available 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.
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat removal. (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THER­MOSTAT - REMOVAL). Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY 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.
CAUTION: Avoid overheating. Do not operate engine for an excessive period of time. Open draincock imme­diately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to approximately 3000 rpm while observing coolant. If internal engine combustion gases are leaking into cooling system, bubbles will appear in coolant. If bubbles do not appear, internal combustion gas leakage is not present.
COOLING SYSTEM DIESEL ENGINE
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS LOW
NOTE: 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 2. Inspect and test thermostat.
3. Coolant level low. 3. Fill cooling system. (Refer to 7 -
4. Temperature gauge not functioning correctly.
5. Engine sensor stuck in range 5. Monitor sensor with DRB III to
6. Engine sensor failed out of range.
7. Electronically Controlled Viscous Fan Drive not operating properly.
1. None. System operating normally.
COOLING - STANDARD PROCEDURE)
4. Check cluster (Refer to 8 ­ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING)
verify sensor reading changes with increasing temperature.
6. A DTC will be set.
7. Check Electronically Controlled Viscous Fan Drive (Refer to 7 ­COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)
TEMPERATURE GAUGE READS HIGH. COOLANT MAY OR MAY NOT BE LEAKING FROM SYSTEM
1. Vehicle overloaded, high ambient (outside) temperatures with A/C turned on, stop and go driving or prolonged operation at idle speeds.
1. Temporary condition, repair not required. Notify customer of vehicle operation instructions located in Owners Manual.
7 - 10 COOLING DR
CONDITION POSSIBLE CAUSES CORRECTION
NOTE: Information on dash cluster is displayed based on broadcast information from ECM. DTC will be set for engine sensor circuit concern.
2. Temperature gauge not functioning correctly.
3. Air trapped in cooling system 3. Drain cooling system (Refer to 7 -
4. Radiator cap faulty. 4. Replace radiator cap.
5. Plugged A/C or radiator cooling fins.
6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -
7. Thermostat stuck shut. 7. Inspect and test thermostat.
8. Bug screen or winter front being used.
9. Electronically controlled viscous fan drive not operating properly.
10. Cylinder head gasket leaking. 10. Check for leaking head gaskets
11. Heater core leaking. 11. Replace heater core.
12. Cooling system hoses leaking. 12. Tighten clamps or Replace
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
14. Accessory drive belt. 14. Inspect. Replace as necessary.
15. Water Pump. 15. Inspect and replace as
16. Engine sensor stuck in range. 16. Monitor sensor with DRBIII to
17. Temperature sensor failed out of range.
2. Check cluster (Refer to 8 ­ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING)
COOLING - STANDARD PROCEDURE) and refill (Refer to 7
- COOLING - STANDARD PROCEDURE)
5. Clean all debris away from A/C and radiator cooling fins.
COOLING - STANDARD PROCEDURE) refill with correct mixture (Refer to 7 - COOLING ­STANDARD PROCEDURE).
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)
(Refer to 7 - COOLING ­DIAGNOSIS AND TESTING).
hoses.
BRAKES/HYDRAULIC/ MECHANICAL - DIAGNOSIS AND TESTING)
necessary.
verify sensor reading changes increase in temperature.
17. A DTC will be set.
TEMPERATURE GAUGE READING INCONSISTENT (ERRATIC, CYCLES OR FLUCTUATES)
1. Heavy duty cooling system, extreme cold ambient (outside) temperature or heater blower motor in high position.
1. None. System operating normally.
DR COOLING 7 - 11
CONDITION POSSIBLE CAUSES CORRECTION
NOTE: Information on dash cluster is displayed based on broadcast data from ECM. DTC will be set for engine sensor circuit wiring.
RADIATOR CAP LEAKING STEAM AND /OR COOLANT INTO RESERVOIR BOTTLE. (TEMPERATURE GAUGE MAY READ HIGH)
HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING.
2. Temperature gauge or sensor defective.
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air trapped in cooling system. 4. Fill cooling system (Refer to 7 -
5. Water pump. 5. Replace water pump.
6. Air leak on suction side of water pump.
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.
2. Check cluster or engine coolant temp sensor (Refer to 8 ­ELECTRICAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING)
COOLING - STANDARD PROCEDURE).
6. Check for leak. (Refer to 7 ­COOLING - DIAGNOSIS AND TESTING)
1. Replace radiator cap, check vent hose between radiator and reservoir bottle for blockage also check reservoir bottle vent for blockage.
NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.
INADEQUATE AIR CONDITIONER PERFORMANCE (COOLING SYSTEM SUSPECTED)
2. Electronically controlled viscous fan drive.
3. Fan blades striking surrounding objects.
4. Electronically controlled viscous fan drive bearing concern.
5. Electronically controlled viscous fan stuck on.
6. Obstructed air flow through radiator.
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.
2. None. Normal condition.
3. Locate contact point and repair as necessary.
4. Check viscous fan drive (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)
5. Check viscous fan drive (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)
6. Remove obstruction.
1. Remove obstruction and/or clean.
2. Check viscous fan drive (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)
3. Inspect air seals, repair or replace as necessary.
7 - 12 COOLING DR
CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE HEATER PERFORMANCE. GAUGE MAY OR MAY NOT READ LOW.
HEAT ODOR 1. Damaged or missing drive line
1. Heavy duty cooling system, and cooler ambient temperatures.
2. Obstruction in heater hoses. 2. Remove hoses, remove
3. Electronically controlled viscous fan stuck on.
4. Water pump damaged. 4. Replace water pump.
heat shields.
2. Electronically controlled viscous fan drive damaged.
1. None. Normal condition.
obstruction. Check viscous fan drive. (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)
1. Repair or replace damaged or missing heat shields.
2. Check viscous fan drive. (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH ­DIAGNOSIS AND TESTING)
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause:
• 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 end of normal range.
• Increasing engine speed up to 2000 rpm with transmission in park or neutral for more airflow is recommended.
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 performed on vehicle that may affect 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 refilling (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 complaint, refer to COOLING SYSTEM DIAGNOSIS CHART BELOW.
These charts are to be used as a quick-reference only. Refer to COOLING SYSTEM DIAGNOSIS CHART
DR COOLING 7 - 13
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.
7 - 14 COOLING 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. 6. (a) Check condition of cap and
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 Diesel).
8. Incorrect coolant concentration. 8. Check coolant. (Refer to
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
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 Diesel) 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.
LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION).
DR COOLING 7 - 15
CONDITION POSSIBLE CAUSES CORRECTION
9. Coolant not flowing through system.
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. 13. Check and correct as necessary.
14. Bug screen or cardboard is being used, reducing air flow.
15. Thermostat partially or completely shut.
16. Viscous fan drive not operating properly.
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
18. Heater core leaking. 18. Check heater core for leaks.
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.
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.
(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).
leaks. (Refer to 7 - COOLING ­DIAGNOSIS AND TESTING).
(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING ­DIAGNOSIS AND TESTING). Repair as necessary.
7 - 16 COOLING DR
CONDITION POSSIBLE CAUSES CORRECTION
Temperature gauge reading is inconsistent (fluctuates, cycles or is erratic)
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. 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.
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
1. Pressure relief valve in radiator cap is defective.
1. Check condition of radiator cap and cap seals. (Refer to 7 ­COOLING/ENGINE/RADIATOR PRESSURE CAP - DIAGNOSIS AND TESTING). Replace cap as necessary.
DR COOLING 7 - 17
CONDITION POSSIBLE CAUSES CORRECTION
COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF. GAUGE READING HIGH OR HOT
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
1. Coolant leaks in radiator, cooling system hoses, water pump or engine.
1. Engine overheating. 1. Check reason for overheating
2. Freeze point of coolant not correct. Mixture is too rich or too lean.
1. Vacuum created in cooling system on engine cool-down is not being relieved through coolant reserve/overflow system.
1. Pressure test and repair as necessary. (Refer to 7 - COOLING ­DIAGNOSIS AND TESTING).
and repair as necessary.
2. Check coolant concentration. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES ­DESCRIPTION).
1. (a) Radiator cap relief valve stuck. (Refer to 7 - COOLING/ ENGINE/RADIATOR PRESSURE CAP - DIAGNOSIS AND TESTING). Replace if necessary.
(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.
(d) Reserve/overflow tank is internally blocked or plugged. Check for blockage and repair as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly.
(Refer to 7 - COOLING/ENGINE/ RADIATOR FAN - REMOVAL)
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.
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.
7 - 18 COOLING 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
1. Has a Diagnostic trouble Code (DTC) been set?
2. Coolant level low. 2. (Refer to 7 - COOLING -
3. Obstructions in heater hose/ fittings.
4. Heater hose kinked. 4. Locate kinked area and repair as
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 air flow to blow it away.
1. (Refer to 25 - EMISSIONS CONTROL - DESCRIPTION) for correct procedures and replace thermostat if necessary
DIAGNOSIS AND TESTING).
3. Remove heater hoses at both ends and check for obstructions.
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.
COOLANT COLOR 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.
COOLANT LEVEL CHANGES IN COOLANT RESERVE/OVERFLOW TANK. TEMPERATURE GAUGE IS IN NORMAL RANGE
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.
1. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES ­DESCRIPTION) Adjust coolant mixture as necessary.
1. A normal condition. No repair is necessary.
DR COOLING 7 - 19
STANDARD PROCEDURE COOLANT LEVEL CHECK
NOTE: Do not remove radiator cap for routine coolant level inspections. The coolant level can be checked at coolant recovery bottle or the coolant degas bottle.
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 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 coolant level should be between the MIN and MAX marks. If the coolant is below the MIN mark, add coolant (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION) to the bottle until the level reaches the MIN mark. Do Not Overfill the bottle by adding fluid above the MAX line. This may cause coolant to spill onto the ground during subse­quent vehicle operation.
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 system. Repeat this procedure until the water drains clean.
REVERSE FLUSHING
Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done 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.
CAUTION: Internal 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 housing. Discon­nect the radiator upper hose from the radiator and attach the flushing gun to the hose. Disconnect 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. Continue 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 thermostat 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 antifreeze/water mixture (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). Refer to Refilling the Cooling System.
7 - 20 COOLING DR
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.
CAUTION: Follow manufacturers instructions when using these products.
DRAINING COOLING SYSTEM - ALL GAS ENGINES
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAIN­COCK 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/overflow 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 cylinder block drain plugs (1).
REFILLING COOLING SYSTEM - ALL GAS ENGINES
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. In order to maintain the required protection for these components and cooling system performance, only use the appropriate fluid (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION) when servicing the vehicle. 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 contaminated, drain, flush, and replace with fresh prop­erly mixed coolant solution.
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK 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.
3. Fill cooling system with the antifreeze mixture (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES ­DESCRIPTION).
4. Fill coolant reserve/overflow tank to MAX mark on bottle.
5. Start and operate engine until thermostat opens (upper radiator hose warm to touch).
6. If necessary, add 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.
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.
DR COOLING 7 - 21
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 coolant 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 TESTING). The coolant need not be removed from tank unless the system is being refilled with fresh mixture.
4. Remove radiator pressure cap.
REFILLING COOLING SYSTEM - 5.9L DIESEL ENGINE
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 refilling 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 distilled water and antifreeze.
3. Fill coolant reserve/overflow tank to the FULL 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 maintain coolant level. This level should be between the ADD and FULL marks. The level in the reserve/overflow tank may drop below the ADD mark after three or four warm-up and cool-down cycles.
ADDING ADDITIONAL COOLANT
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. In order to maintain the required protection for these components and cooling system performance, only use the appropriate fluid (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION) when servicing the vehicle. 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 contaminated, drain, flush, and replace with fresh prop­erly mixed coolant solution. 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 contaminated, drain, flush, and replace with fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
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 pro­duces corrosion.
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.
7 - 22 COOLING DR
SPECIFICATIONS TORQUE
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Bolt - Automatic Belt Tensioner to Block 41 30 ­Bolt - Automatic Belt Tensioner Pulley 61 45 ­Bolt - Automatic Belt Tensioner Pulley - Diesel 43 32 ­Engine Mounted Fan Shroud Brackets (Upper and Lower) 24 18 ­Fan Shroud Ring to Fan Shroud Brackets 24 18 ­Bolt - Block Heater 2 - 17 Bolts - Generator/Compressor Mounting Bracket
# 1 and 2 54 40 -
# 3 40 30 ­Bolts - Generator/Compressor Mounting Bracket - Diesel 24 18 ­Bolts - Fan Shroud to Radiator Mounting - All Except 5.9L
Diesel
5.9L Diesel 12 - 105 Bolts - Radiator to Support 8 - 75 Bolts - Fan Blade to Viscous Fan Drive 24 18 ­Fan Drive - All Except 8.0L/5.9L Diesel 50 37 -
8.0L/5.9L Diesel 115 85 ­Bolt - Idler Pulley 54 40 ­Bolt - Idler Pulley - Diesel 43 32 ­Bolts - Thermostat Housing - All Except 5.9L Diesel 13 - 112 Bolts - Thermostat Housing 5.9L 23 16 ­Bolts - Thermostat Housing - Diesel 10 - 89 Bolts - Power Steering Oil Cooler 8 - 75 Bolts - Transmission Auxiliary Oil Cooler 6 - 55 Nuts - Transmission Oil Cooler Tube 31 24 ­Bolts - Coolant Bottle 8 - 75 Tube Nuts - Transmission Oil Cooler to Transmission
5.9L/46RE 31 24 -
3.7L/4.7L/5.7L/45RFE 20 18 ­Bolts - Water Pump - Diesel 24 18 ­Bolts - Water Pump - 4.7L 58 43 ­Block Heater - Diesel 75 55 ­Transmission Oil Cooler - Diesel
M8 24 18 -
M12 77 57 -
6-55
DR COOLING 7 - 23
SPECIFICATIONS - FILL VOLUMES
DESCRIPTION SPECIFICATION
Metric Standard
3.7L Engine 4.7L 5 qts
4.7L Engine 5.6L 6.0 qts.
5.7L Engine 6.6L 7.0 qts.
8.3L SRT-10 Engine Oil Service Quanity
8.3L SRT-10 Engine Overhaul Quanity
5.9L Diesel Engine 28L 29.5 qts.
8.9L 8.75 qts.
9.4L 10.0 qts.
7 - 24 COOLING DR
SPECIAL TOOLS COOLING
Adapter Pins 8346
Pliers Constant Pressure Hose Clamp - 6094
3/8” Quick Connect Release Tool - 6935
Spanner Wrench - 6958
Cooling System Pressure Tester - 7700A
Coolant Refractometer 8286
DR ACCESSORY DRIVE 7 - 25
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
TENSIONER-BELT
DESCRIPTION ................................26
OPERATION ..................................26
REMOVAL
INSTALLATION
BELT-DRIVE
DIAGNOSIS AND TESTING
REMOVAL
INSTALLATION
7 - 26 ACCESSORY DRIVE DR
TENSIONER-BELT
DESCRIPTION
Correct drive belt tension is required to ensure opti­mum performance of the belt driven engine accesso­ries. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life.
It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times.
CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner.
OPERATION
The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt.
REMOVAL
3.7L/4.7L ENGINE
On 3.7L and 4.7L engines, the tensioner is equipped with an indexing tang on back of ten­sioner and an indexing stop on tensioner housing. If a new belt is being installed, tang must be within approximately 24 mm (.94 inches) of 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 compressor, power steering pump, water pump, idler pulley or generator)
• A pulley on an engine accessory being loose
• Misalignment of an engine accessory
• Belt incorrectly routed.
NOTE: A used belt should be replaced if tensioner indexing arrow has moved to the minimum tension indicator. Tensioner travel stops at this point.
1. Remove accessory drive belt (Refer to 7 - COOL­ING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
2. Remove tensioner (3) assembly from mounting bracket.
WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
3. Remove pulley bolt. Remove pulley from tensioner.
DR ACCESSORY DRIVE 7 - 27
5.7L ENGINE
1. Remove accessory drive belt (Refer to 7 - COOL­ING/ACCESSORY DRIVE/DRIVE BELTS ­REMOVAL).
2. Remove tensioner (1) and mounting bracket.
3. Remove the tensioner assembly from the mounting bracket.
5.9L DIESEL
The 5.9L diesel engine accessory drive system (with a/c) consists of :
• Generator Pulley (1)
• Water Pump Pulley (2)
• Idler Pulley (3)
• Power Steering Pump Pulley (4)
• Radiator Fan Pulley (5)
• Crankshaft Pulley (6)
• Automatic Tensioner (7)
• A/C Compressor Pump Pulley (8)
WARNING: BECAUSE OF HIGH SPRING PRES­SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC 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 and remove ten­sioner (7).
7 - 28 ACCESSORY DRIVE DR
8.3L ENGINE
1. Remove the air intake tube between intake mani­fold and air filter assembly (Refer to 9 - ENGINE/ AIR INTAKE SYSTEM/AIR CLEANER ELEMENT ­REMOVAL).
2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys.
3. Remove accessory drive belt.
4. Gently release tensioner.
5. Remove tensioner mounting nut (1) .
INSTALLATION
3.7L/4.7L ENGINE
1. Install pulley and pulley bolt to tensioner (3). Tighten bolt to 61 N·m (45 ft. lbs.) torque.
2. An indexing slot is located on back of tensioner (3). Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt (2) to 41 N·m (30 ft. lbs.).
3. Install accessory drive belt (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - INSTALLA­TION).
4. Check belt indexing marks.
DR ACCESSORY DRIVE 7 - 29
5.7L ENGINE
1. Install tensioner (1) on to the mounting bracket. Tighten bolt (2) to 41 N·m (30 ft. lbs.).
2. Install tensioner and bracket assembly
3. Install accessory drive belt (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS ­INSTALLATION).
5.9L DIESEL
The 5.9L diesel engine accessory drive system (with a/c) consists of :
• Generator Pulley (1)
• Water Pump Pulley (2)
• Idler Pulley (3)
• Power Steering Pump Pulley (4)
• Radiator Fan Pulley (5)
• Crankshaft Pulley (6)
• Automatic Tensioner (7)
• A/C Compressor Pump Pulley (8)
1. Install tensioner assembly (7) to water inlet 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.
2. Install drive belt (Refer to 7 - COOLING/ACCES­SORY DRIVE/DRIVE BELTS - INSTALLATION).
7 - 30 ACCESSORY DRIVE DR
8.3L ENGINE
NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.
1. Install tensioner and mounting nut (1). Torque mounting nut to 41 N·m (30 ft. lbs.).
2. Install accessory drive belt (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - INSTALLA­TION).
3. Install the air intake tube between intake manifold and air filter assembly.
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