Jeep Liberty 2.8L Diesel 2006, Liberty 2.8L Diesel 2005 User Manual
GROUP TAB LOCATOR
Maintenance Schedules
0
Cooling - 2.5L / 2.8L Diesel
7
8E
8F
11
14
21
25
Service Manual Comment Forms (Rear of Manual)
Electronic Control Modules
Engine Systems
Ignition Control
8I
Engine
9
Exhaust System and Turbocharger
Fuel System
Automatic Transmission - 545RFE
Emissions Control - 2.5L / 2.8L Turbo Diesel
KJ MAINTENANCE SCHEDULES 0 - 1
MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page
MAINTENANCE SCHEDULES FOR ALL
MARKETS EXCEPT U.S., CANADA and
MEXICO
DESCRIPTION — DIESEL ENGINES .........1
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO
DESCRIPTION — DIESEL ENGINES
Maintenance Schedule Information not included in
this section, is located in the appropriate Owner’s
Manual.
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
• Extensive engine idling.
• Driving in dusty conditions.
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
NOTE: Most vehicles are operated under the conditions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are
not operated under any of the conditions listed under
Schedule 9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
• Check the windshield washer solvent and add if
required.
Once a Month
• Check the tire pressure and look for unusual
wear or damage.
• Inspect the battery and clean and tighten the
terminals as required.
• Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and add as needed.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect the brake hoses.
• Check the manual transmission fluid level — if
equipped.
• Check the coolant level, hoses, and clamps.
• Inspect engine accessory drive belts. Replace as
necessary.
• Inspect for the presence of water in the fuel filter/water separator unit.
• Rotate the tires.
Schedule “B”
Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
• Extensive engine idling.
• Driving in dusty conditions.
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
0 - 2 MAINTENANCE SCHEDULES KJ
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Change the engine oil and engine oil filter. XXXXX
Inspect the ball joints. XXXXX
Inspect engine accessory drive belt. XXXX
Replace engine accessory drive belt. X
Inspect the engine air filter element.
Replace as necessary.
Replace the engine air filter element. X X
Replace the engine timing belt. X
Inspect idler pulleys and timing belt
tensioner‡.
Replace fuel filter/water separator unit. X X
Inspect the brake linings. XXXXX
Drain and refill the front and rear axle fluid. X X
Drain and refill automatic transmission fluid
and replace transmission main sump filter.
XXX
X
X
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000 km
Change the engine oil and engine oil filter. XXXX X
Inspect the ball joints. XXXX X
Inspect engine accessory drive belt. XXXX X
Replace engine accessory drive belt. X
Inspect the engine air filter element.
Replace as necessary.
Replace the engine air filter element. X X X
Inspect idler pulleys and timing belt
tensioner‡.
Replace the engine timing belt. X
Inspect the brake linings. XXXX X
Drain and refill the front and rear axle fluid. X X X
Replace the fuel filter/water separator unit. X X X
Drain and refill the transfer case fluid. X
Drain and refill the automatic transmission
fluid and replace transmission main sump
filter.
XX
X
X
KJ MAINTENANCE SCHEDULES 0 - 3
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
Kilometers 110 000 km 120 000 km 130 000 km 140 000 km 150 000 km 160 000 km
Change the engine oil and
engine oil filter.
Inspect the ball joints. XXXXXX
Inspect the engine air filter
element. Replace as
necessary.
Replace the engine air filter
element.
Inspect engine accessory
drive belt.
Replace engine accessory
drive belt.
Inspect the idler pulleys and
timing belt tensioner‡.
Replace the engine timing
belt.
Inspect the brake linings. XXXXXX
Drain and refill the front and
rear axle fluid.
Replace the fuel filter/water
separator unit.
Flush and replace the engine
coolant.
Drain and refill automatic
transmission fluid and replace
transmission filter (s).
XXXXXX
XXX
XXX
XXXX X
X
X
X
XXX
XXX
X
X
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
‡ Replace if there is superficial wear, bearing clearance, or evident grease leak.
0 - 4 MAINTENANCE SCHEDULES KJ
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
Schedule “A”
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000 km
Change the engine oil and engine oil
filter.
Inspect the ball joints. XXXXX
Inspect the brake linings. X X
Inspect the engine air filter element.
Replace as necessary.
Replace the engine air filter element. X X
Inspect the engine accessory drive belt. XXXXX
Replace the engine accessory drive
belt.
Replace the fuel filter/water separator
unit.
Inspect idler pulleys, and timing belt
tensioner‡.
Replace the engine timing belt. X
Inspect the transfer case fluid. X
XXXXX
XXX
X
XXXXX
X
Kilometers 120 000 km 140 000 km 160 000 km 180 000 km
Change the engine oil and engine oil filter. X X X X
Inspect the ball joints. X X X X
Inspect the brake linings. X X
Inspect the engine accessory drive belt. X X X X
Inspect the engine air filter element. Replace
as necessary.
Replace the engine air filter element. X X
Replace the fuel filter/water separator unit. X X X X
Flush and replace the engine coolant. X
Inspect the transfer case fluid. X
Drain and refill the transfer case fluid. X
Drain and refill automatic transmission fluid
and replace transmission filter (s).
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
‡ Replace if there is superficial wear, bearing clearance, or evident grease leak.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
XX
X
KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 1
COOLING - 2.5L/2.8L TURBO DIESEL
TABLE OF CONTENTS
page page
COOLING - 2.5L/2.8L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM .........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK .................1
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION ....................1
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TEST....................2
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTICS (OBD) ...................2
DIAGNOSIS AND TESTING - COOLING
SYSTEM .............................3
COOLING - 2.5L/2.8L TURBO
DIESEL
DESCRIPTION - COOLING SYSTEM
The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible, maintains
normal operating temperature and prevents overheating.
The cooling system also provides a means of heating the passenger compartment. The cooling system
is pressurized and uses a centrifugal water pump to
circulate coolant throughout the system. A separate
and remotely mounted, pressurized coolant tank
using a pressure/vent cap is used.
COOLING SYSTEM COMPONENTS
The cooling system consists of:
• Charge Air Cooler
• Electric Cooling Fans
• A aluminum-core radiator with plastic side
tanks
• A separate pressurized coolant tank
• A pressure/vent cap on the coolant tank
• Fan shroud
• Thermostat
• Coolant
• Low coolant warning lamp
• Coolant temperature gauge
• Water pump
• Hoses and hose clamps
STANDARD PROCEDURE - COOLING
SYSTEM - REVERSE FLUSHING ...........7
CLEANING .............................8
INSPECTION ...........................8
SPECIFICATIONS
SPECIFICATIONS - COOLING SYSTEM
CAPACITY ............................8
SPECIFICATIONS - TORQUE .............8
ACCESSORY DRIVE .......................9
ENGINE ...............................16
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use the following procedures:
(1) If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper
radiator hose. If it is hot, coolant is circulating.
WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
(2) Remove pressure/vent cap when engine is cold,
idle engine until thermostat opens, you should
observe coolant flow while looking down in the coolant recovery pressure container. Once flow is
detected install the pressure/vent cap.
DIAGNOSIS AND TESTING - COOLING SYSTEM AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aeration. Aeration will draw air into the water pump
resulting in the following:
• High reading shown on the temperature gauge.
• Loss of coolant flow through the heater core.
• Corrosion in the cooling system.
7 - 2 COOLING - 2.5L/2.8L TURBO DIESEL KJ
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
• Water pump seal may run dry, increasing the
risk of premature seal failure.
• Combustion gas leaks into the coolant can also
cause aeration.
DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TEST
WARNING: THE WARNING WORDS “DO NOT OPEN
HOT” ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
With engine not running, remove pressure/vent cap
from the coolant recovery pressure container and
wipe the filler neck sealing seat clean. The coolant
level in the recovery pressure container should be
full.
Attach the Cooling System Tester 7700 or equivalent to the radiator, as shown in (Fig. 1) and apply
104 kPa (15 psi) pressure. If the pressure drops more
than 13.8 kPa (2 psi) in 2 minutes, inspect all points
for external leaks.
All radiator and heater hoses should be shaken
while at 104 kPa (15 psi), since some leaks occur only
while driving due to engine movement.
If there are no external leaks, after the gauge dial
shows a drop in pressure, detach the tester. Start
engine and run until the thermostat opens, allowing
the coolant to expand. Reattach the cooling system
tester. If the needle on the dial fluctuates it indicates
a combustion leak, usually a head gasket leak.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL
BUILD UP RAPIDLY. EXCESSIVE 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 the needle on the dial does not fluctuate, raise
the engine rpm a few times. If an abnormal amount
of coolant or steam emits from the tailpipe, it may
indicate a coolant leak caused by a faulty head gasket, cracked engine block, or cracked cylinder head.
There may be internal leaks that can be determined by removing the oil dipstick. If water globules
appear intermixed with the oil it will indicate an
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
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 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).
Fig. 1 PRESSURE TESTING COOLING SYSTEM
1 - COOLANT PRESSURE TESTER
2 - COOLANT RECOVERY PRESSURE CONTAINER
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.
KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 3
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM
Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as
the following may be the cause:
(1) PROLONGED IDLE, VERY HIGH AMBIENT
TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
OR STEEP GRADES.
• Idle with A/C off when temperature gauge is at
end of normal range.
(2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(3) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been performed on vehicle that may effect cooling system.
This may be:
COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS LOW
1. Diesel engines, due to their
inherent efficiency are slower to
warm up than gasoline powered
engines, and will operate at lower
temperatures when the vehicle is
unloaded.
2. Is the temperature gauge
connected to the temperature gauge
coolant sensor on the engine?
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.
• Engine adjustments (incorrect timing)
• Slipping engine accessory drive belt
• Brakes (possibly dragging)
• Changed parts (incorrect water pump)
• Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating complaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only.
1. The low gauge reading may be
normal. Refer to thermostats in the
manual text for information. See
Thermostat Diagnosis-Diesel
Engine.
2. Check, the engine temperature
sensor connector in the engine
compartment.
3. Check gauge operation. Repair
as necessary.
4. Check coolant level in the
coolant tank. Inspect system for
leaks. Repair leaks as necessary.
Refer to the Coolant section for
WARNINGS and precautions
before removing the pressure cap.
5. Inspect heater and repair as
necessary. Refer to Heating and
Air Conditioning for procedures.
7 - 4 COOLING - 2.5L/2.8L TURBO DIESEL KJ
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS HIGH. COOLANT
MAY OR MAY NOT BE LOST
OR LEAKING FROM
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) temperature and the air
conditioning is on. Higher altitudes
could aggravate these conditions.
2. Temperature gauge reading
incorrectly.
3. Coolant low in coolant tank and
radiator.
4. Pressure cap not installed tightly. If
cap is loose, boiling point of coolant
will be lowered.
5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap and
6. Freeze point of antifreeze not
correct. Mixture may be too rich.
7. Coolant not flowing through
system.
8. Radiator or A/C condenser fins are
dirty or clogged.
9. Radiator core is corroded or
plugged.
10. Aftermarket A/C installed without
proper A/C condenser.
11. Dragging Brakes. 11. Check and correct as
12. Non-factory bug screen is being
used reducing air flow.
13. Thermostat partially or completely
shut. This is more prevalent on high
mileage vehicles.
14. Cylinder head gasket leaking. 14. Check cylinder head gasket for
15. Heater core leaking. 15. Check heater core for leaks.
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
normal range, determine the
cause for the overheating and
repair.
2. Check gauge. Refer to I/P
group.
3. Check for coolant leaks and
repair as necessary.
4. Tighten cap.
cap seals. (b) Check condition of
coolant tank filler neck. Make sure
it does not leak pressure.
6. Check antifreeze. Adjust
antifreeze-to-water ratio as
required.
7. Check for coolant flow in
coolant tank with engine warm and
thermostat open. Coolant should
be observed flowing through the
tank. If flow is not observed,
determine reason for lack of flow
and repair as necessary.
8. Clean debris from radiator or
A/C condenser
9. Have radiator re-cored or
replaced.
10. Install proper A/C condenser.
necessary.
12. Only a factory screen should
be used.
13. Check thermostat and replace
if necessary.
leaks.
Repair as necessary.
KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 5
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
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. Fluctuation is also influenced
by loads, outside temperature and
extended idle time with diesel
engines.
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 starting a
warm-up (hot) engine.
5. Coolant level low in the coolant
tank (air will build up in the cooling
system causing the thermostat to
open late).
6. Cylinder head gasket leaking
allowing exhaust gases to enter the
cooling system causing the
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 allowing air to build up in
the cooling system causing the
thermostat to open late.
1. A normal condition. No
correction is necessary.
2. Check operation of gauge and
repair as necessary.
3. A normal condition. No
correction needed. Gauge should
return to normal range after
vehicle is driven.
4. A normal condition. No
correction needed. Gauge should
return to normal after a few
minutes of engine operation.
5. Check and correct coolant
leaks.
6. (a) Check for cylinder head
gasket leaks with a commercially
available leak tester. (b) Check for
coolant in engine oil. Inspect for
white steam emitting from exhaust
system. Repair as necessary.
7. Check water pump and replace
as necessary.
8. Check and correct as
necessary.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS
BLOWING OFF STEAM
AND/OR COOLANT.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT TANK
COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP BLOWOFF.
GAUGE IS READING HIGH
OR HOT
1. Pressure relief valve in pressure/
vent cap is defective.
2. Head gasket leak or cracked
cylinder head.
1. Coolant leaks in radiator, cooling
system hoses, water pump, or
engine.
1. Check condition of pressure/
vent cap and cap seals.
2. Repair as necessary.
1. Pressure test cooling system
and repair as necessary.
7 - 6 COOLING - 2.5L/2.8L TURBO DIESEL KJ
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HOSE OR HOSES
COLLAPSE WHEN ENGINE
IS COOLING
NOISY FAN 1. Cooling fan blades loose. 1. Replace cooling fan assembly.
INADEQUATE AIR
CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)
1. Vacuum created in cooling system
on engine cool-down is not being
relieved through pressure/vent cap.
2. Cooling fan blades striking a
surrounding object.
3. Air obstructions at radiator or A/C
condenser.
1. Radiator and/or A/C condenser is
restricted, obstructed or dirty (insects,
leaves, etc.)
2. Engine is overheating (heat may
be transferred from radiator to A/C
condenser. High Under hood
temperatures due to engine
overheating may also transfer heat to
A/C condenser).
3. The cooling system is equipped
with air seals at the radiator and/or
A/C condenser. If these seals are
missing or damaged, not enough air
flow will be pulled through the
radiator and A/C condenser.
1. Cap relief valve stuck. Replace
if necessary.
2. Locate point of fan blade
contact and repair as necessary.
3. Remove obstructions or clean
debris from radiator or A/C
condenser.
1. Remove restriction or clean
debris from radiator or A/C
condenser.
2. Correct overheating condition.
3. Check for missing or damaged
air seals. Repair as necessary.
INADEQUATE HEATER
PERFORMANCE. MAY BE
ACCOMPANIED BY LOW
GAUGE READING
1. Diesel engines, due to their
inherent efficiency are slower to
warm up than gasoline powered
engines, and will operate at lower
temperatures when the vehicle is
unloaded.
2. Coolant level low. 2. Pressure test cooling system.
3. Obstruction in heater hose fitting at
engine.
4. Heater hose kinked. 4. Locate kinked area. Repair as
5. Water pump is not pumping water
to 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.
The accessory drive belt may also be
slipping causing poor water pump
operation.
1. The lower gauge reading may
be normal.
Repair leaks as necessary.
3. Remove heater hoses and
check for obstructions. Repair as
necessary.
necessary.
5. Refer to water pumps in this
group. Repair as necessary. If a
slipping belt is detected, refer to
Engine Accessory Drive Belts in
this group. Repair as necessary.
KJ COOLING - 2.5L/2.8L TURBO DIESEL 7 - 7
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HEAT ODOR 1. Various heat shields are used at
certain drive line components. One or
more of these shields may be
missing.
2. Is temperature gauge reading
above the normal range?
3. Is the Cooling fan operating
correctly?
4. Has undercoating been applied to
any unnecessary components?
STEAM IS COMING FROM
FRONT OF VEHICLE NEAR
GRILL AREA WHEN
WEATHER IS WET, ENGINE
IS WARMED UP AND
RUNNING, AND VEHICLE IS
STATIONARY.
TEMPERATURE GAUGE IS
IN NORMAL RANGE
COOLANT ODOR 1. Coolant color is not necessarily an
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.
indication of adequate corrosion or
temperature protection. Do not rely
on coolant color for determining
condition of coolant.
1. Locate missing shields. Repair
or replace as necessary.
2. Refer to the previous
Temperature Gauge Reads High in
these Diagnostic Charts. Repair as
necessary.
3. Refer to Cooling System Fan in
this group for diagnosis. Repair as
necessary.
4. Clean undercoating as
necessary.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
1. Refer to Coolant in this group
for antifreeze tests. Adjust
antifreeze-to-water ratio as
necessary.
COOLANT LEVEL CHANGES
IN COOLANT 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 HOT and
COLD marks at normal engine
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
STANDARD PROCEDURE - COOLING SYSTEM REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-110 kPa (14-to -16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
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.
1. This a normal condition. No
repair necessary.
CHEMICAL CLEANING
If visual inspection indicates the formation of
sludge or scaly deposits, use a radiator cleaner
(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fittings. Attach a section of 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.
7 - 8 COOLING - 2.5L/2.8L TURBO DIESEL KJ
COOLING - 2.5L/2.8L TURBO DIESEL (Continued)
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator
is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equipment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE
Drain the cooling system (Refer to 7 - COOLING STANDARD PROCEDURE). 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. Attach a lead away hose to the
water pump inlet fitting.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water supply hose and air supply hose
to the 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. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermostat housing (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL).
Install the thermostat and housing with a replace-
ment gasket (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PROCEDURE).
CLEANING
Drain cooling system and refill with clean water.
Refer to procedures in this section. Run engine with
pressure/vent cap installed until upper radiator hose
is hot. Stop engine and drain water from system. If
water is dirty; fill, run, and drain system again, until
water runs clear.
INSPECTION
After performing a cleaning/flush procedure,
inspect all hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for
leaks.
SPECIFICATIONS
SPECIFICATIONS - COOLING SYSTEM CAPACITY
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Cooling System With
Auxiliary Heater
Cooling System With Out
Auxiliary Heater
16.6 Liters (17.5 qts.)
13.8 Liters (14.6 qts.)
SPECIFICATIONS - TORQUE
2.5L/2.8L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Accessory Drive Belt Idler
Bolt
Accessory Drive Belt
Tensioner Bolt
Cooling Fan Support Bolts 47.1 35 —
Thermostat Housing Bolts 27.5 21 —
Water Pump Housing Nuts 24.4 18 215
53 39 —
47.1 35 —
KJ ACCESSORY DRIVE 7 - 9
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS - ACCESSORY BELT
TENSION .............................9
BELT TENSIONERS
DESCRIPTION ..........................9
OPERATION ............................9
REMOVAL .............................10
INSTALLATION .........................10
DRIVE BELT
DESCRIPTION .........................11
ACCESSORY DRIVE
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE
BELT
2.5L/2.8L DIESEL ENGINE
A/C Compressor/
Generator
Power Steering Belt Dynamic Tensioner
GAUGE
Dynamic Tensioner
OPERATION-ACCESSORY DRIVE BELT ......11
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT .........................11
REMOVAL .............................13
INSTALLATION .........................13
IDLER PULLEYS
REMOVAL .............................14
INSTALLATION .........................15
BELT TENSIONERS
DESCRIPTION
This engine is equipped with a spring loaded automatic belt tensioner (Fig. 1). 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.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
Fig. 1 ACCESSORY BELT ROUTING
1 - IDLER PULLEY
2 - GENERATOR
3 - IDLER PULLEY
4 - A/C COMPRESSOR
5 - COOLING FAN SUPPORT
6 - VIBRATION DAMPER
7 - BELT TENSIONER
8 - POWER STEERING PUMP
9 - ACCESSORY DRIVE BELT
10 - VISCOUS HEATER
7 - 10 ACCESSORY DRIVE KJ
BELT TENSIONERS (Continued)
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.
If a new belt is being installed, the arrow must be
within approximately 3 mm (1/8 in.) of indexing mark.
Belt is considered new if it has been used 15 minutes
or less. If this 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.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove accessory drive belt (Fig. 2)(Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(3) Remove belt tensioner retaining bolt and
remove tensioner from bracket (Fig. 3).
Fig. 2 ACCESSORY BELT ROUTING
1 - IDLER PULLEY
2 - GENERATOR
3 - IDLER PULLEY
4 - A/C COMPRESSOR
5 - COOLING FAN SUPPORT
6 - VIBRATION DAMPER
7 - BELT TENSIONER
8 - POWER STEERING PUMP
9 - ACCESSORY DRIVE BELT
10 - VISCOUS HEATER
Fig. 3 BELT TENSIONER ASSEMBLY
1 - ACCESSORY BELT TENSIONER RETAINING BOLT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENSIONER
4 - BRACKET
5 - POWER STEERING PUMP
6 - POWER STEERING PUMP RETAINING BOLTS
7 - POWER STEERING PUMP PULLEY RETAINING BOLTS
INSTALLATION
(1) Install belt tensioner on bracket (Fig. 3).
Torque retaining bolt to 47.1N·m.
(2) Install accessory drive belt (Fig. 2)(Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(3) Connect negative battery cable.
KJ ACCESSORY DRIVE 7 - 11
DRIVE BELT
DESCRIPTION
The accessory drive belt is a serpentine type belt
(Fig. 4). Satisfactory performance of these belts
depends on belt condition and proper belt tension.
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. 5), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must
be replaced (Fig. 5). 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. 4 ACCESSORY BELT ROUTING
1 - IDLER PULLEY
2 - GENERATOR
3 - IDLER PULLEY
4 - A/C COMPRESSOR
5 - COOLING FAN SUPPORT
6 - VIBRATION DAMPER
7 - BELT TENSIONER
8 - POWER STEERING PUMP
9 - ACCESSORY DRIVE BELT
10 - VISCOUS HEATER
OPERATION-ACCESSORY DRIVE BELT
The accessory drive belts form the link between
the engine crankshaft and the engine driven accessories.
Fig. 5 BELT WEAR PATTERN
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.
7 - 12 ACCESSORY DRIVE KJ
DRIVE BELT (Continued)
ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (One or more ribs
has separated from belt body)
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
BELT SLIPS 1. Belt slipping because of
1. Foreign objects imbedded in
pulley grooves.
2. Installation damage 2. Replace belt
2. Abrasive environment 2. Clean pulley(s). Replace belt if
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove
tips
5. Belt rubber deteriorated 5. Replace belt
insufficient tension
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
3. Driven component bearing failure
(seizure)
4. Belt glazed or hardened from
heat and excessive slippage
1. Remove foreign objects from
pulley grooves. Replace belt.
necessary
4. Replace pulley. Inspect belt.
1. Inspect/Replace tensioner if
necessary
2. Replace belt and clean pulleys
3. Replace faulty component or
bearing
4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
2. Pulley groove tip has worn away
rubber to tensile member
9GROOVE JUMPING9
(Belt does not maintain correct
position on pulley)
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Incorrect belt tension 1. Inspect/Replace tensioner if
2. Pulley(s) not within design
tolerance
3. Foreign object(s) in grooves 3. Remove foreign objects from
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
1. Incorrect belt tension 1. Replace Inspect/Replace
2. Tensile member damaged during
belt installation
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
1. Replace belt
2. Replace belt
necessary
2. Replace pulley(s)
grooves
tensioner if necessary
2. Replace belt
and belt
KJ ACCESSORY DRIVE 7 - 13
DRIVE BELT (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
1. Tension sheeting contacting
stationary object
2. Excessive heat causing woven
fabric to age
3. Tension sheeting splice has
fractured
1. Incorrect belt tension 1. Inspect/Replace tensioner if
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
5. Locate defective driven
component and repair
1. Correct rubbing condition
2. Replace belt
3. Replace belt
necessary
4. Replace belt
REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located
in the engine compartment.
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVERE DAMAGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic (spring loaded) belt tensioner.
(1) Disconnect negative battery cable.
(2) Rotate belt tensioner until it contacts its stop.
Remove belt, then slowly rotate the tensioner into
the freearm position.
INSTALLATION
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located
in the engine compartment.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt tensioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.
7 - 14 ACCESSORY DRIVE KJ
DRIVE BELT (Continued)
(2) Install new belt. Route the belt around all pulleys except the idler pulley (Fig. 6). Rotate the tensioner arm until it contacts its stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys (Fig. 6).
IDLER PULLEYS
REMOVAL
CAUTION: The retaining bolts on the idler pulleys
are left hand thread.
(1) Disconnect negative battery cable.
(2) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(3) Remove idler pulley retaining bolts and pulleys
(Fig. 7) (Fig. 8).
Fig. 6 ACCESSORY BELT ROUTING
1 - IDLER PULLEY
2 - GENERATOR
3 - IDLER PULLEY
4 - A/C COMPRESSOR
5 - COOLING FAN SUPPORT
6 - VIBRATION DAMPER
7 - BELT TENSIONER
8 - POWER STEERING PUMP
9 - ACCESSORY DRIVE BELT
10 - VISCOUS HEATER
Fig. 7 COOLING FAN SUPPORT
1 - IDLER PULLEY
2 - COOLING FAN SUPPORT
3 - RETAINING BOLTS
4 - ENGINE LIFT HOOK
KJ ACCESSORY DRIVE 7 - 15
IDLER PULLEYS (Continued)
INSTALLATION
(1) Install idler pulleys and retaining bolts (Fig. 7)
(Fig. 8). Torque bolts to 53N·m.
(2) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(3) Connect negative battery cable.
Fig. 8 VIBRATION DAMPER AND IDLER PULLEY
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
2 - VIBRATION DAMPER/CRANKSHAFT PULLEY
3 - IDLER PULLEY
7 - 16 ENGINE KJ
ENGINE
TABLE OF CONTENTS
page page
COOLANT
STANDARD PROCEDURE
STANDARD PROCEDURE—DRAINING
COOLING SYSTEM ....................16
STANDARD PROCEDURE - COOLING
SYSTEM FILLING .....................17
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM ....................17
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION .........................17
OPERATION ...........................17
COOLING FAN
REMOVAL
REMOVAL - COOLING FAN ..............17
REMOVAL - COOLING FAN SUPPORT .....17
CLEANING ............................17
INSPECTION ..........................17
INSTALLATION
INSTALLATION - COOLING FAN ..........18
INSTALLATION - COOLING FAN SUPPORT . . 18
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE .....18
REMOVAL - HEATER CORE HOSES .......18
INSTALLATION
INSTALLATION - UPPER RADIATOR HOSE . . 19
INSTALLATION – HEATER CORE HOSES . . . 19
ENGINE COOLANT TEMP SENSOR
DESCRIPTION .........................19
OPERATION ...........................19
REMOVAL .............................20
INSTALLATION .........................20
ENGINE COOLANT THERMOSTAT
DESCRIPTION .........................20
OPERATION ...........................20
REMOVAL .............................20
INSTALLATION .........................21
FAN DRIVE VISCOUS CLUTCH
DESCRIPTION .........................21
OPERATION ...........................22
DIAGNOSIS AND TESTING - FAN DRIVE
VISCOUS CLUTCH ....................22
REMOVAL .............................22
INSTALLATION .........................23
RADIATOR
REMOVAL .............................23
INSTALLATION .........................24
WATER PUMP
DESCRIPTION .........................24
OPERATION ...........................24
REMOVAL - WATER PUMP ................24
CLEANING ............................24
INSTALLATION .........................25
RADIATOR PRESSURE CAP
DESCRIPTION .........................25
OPERATION ...........................25
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP...............25
DIAGNOSIS AND TESTING - PRESSURE
RELIEF TEST ........................25
CLEANING ............................26
INSPECTION ..........................26
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS ...........26
OPERATION - HOSE CLAMPS .............27
COOLANT
STANDARD PROCEDURE
STANDARD PROCEDURE—DRAINING COOLING SYSTEM
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
(1) DO NOT remove radiator cap first. With engine
cold, raise vehicle on a hoist and locate radiator
draincock.
NOTE: Radiator draincock is located on the Right/
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. Open draincock
and drain coolant from radiator. This will empty the
coolant reserve/overflow tank. The coolant does not
have to be removed from the tank unless the system
is being refilled with a fresh mixture. Remove radiator cap and continue draining cooling system.
KJ ENGINE 7 - 17
COOLANT (Continued)
STANDARD PROCEDURE - COOLING SYSTEM FILLING
Remove pressure/vent cap and fill system, using a
50/50 mix of Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula and distilled water.
Continue filling system until full. Be careful not
to spill coolant on drive belts or the generator.
Fill coolant recovery pressure container to at least
the MAX mark with 50/50 solution. It may be necessary to add coolant to the coolant recovery pressure
container after three or four warm up/cool down
cycles to maintain coolant level between the MAX
and MIN mark. This will allow trapped air to be
removed from the system.
STANDARD PROCEDURE - REFILLING COOLING SYSTEM
(1) Tighten the radiator draincock and the cylinder
block drain plug(s) (if removed).
CAUTION: Failure to purge air from the cooling system can result in an overheating condition and
severe engine damage.
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and
returned to a proper level in the radiator.
The coolant reservoir/overflow system has a radiator mounted pressurized cap, an overflow tube, and a
plastic coolant reservoir/overflow tank, mounted to
the right side of the cowl. It is mounted to the cowl
with two nuts on top, and a slide bracket on the bottom.
OPERATION
The pressure chamber keeps the coolant free of
trapped air, provides a volume for expansion and contraction, and provides a convenient and safe method
for checking and adjusting coolant level at atmospheric pressure. It also provides some reserve coolant to cover minor leaks, evaporation or boiling
losses. The overflow chamber allows coolant recovery
in case of an overheat.
COOLING FAN
(2) Fill system using a 50/50 mixture of ethyleneglycol antifreeze and low mineral content water, until
coolant remains in the bottom of the coolant reserve/
overflow. Install radiator cap.
(3) With heater control unit in the HEAT position,
operate engine with radiator cap in place.
(4) After engine has reached normal operating
temperature, shut engine off and allow it to cool.
When engine is cooling down, coolant will be drawn
into the radiator from the reserve/overflow tank.
(5) Add coolant to reserve/overflow tank as necessary. Only add coolant to the reserve/overflow
tank when the engine is cold. Coolant level in a
warm engine will be higher due to thermal
expansion.
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION
This system works along with the radiator pressure cap. This is done by using thermal expansion
and contraction of the coolant to keep the coolant
free of trapped air. It provides:
• A volume for coolant expansion and contraction.
• A convenient and safe method for checking/ad-
justing coolant level at atmospheric pressure. This is
done without removing the radiator pressure cap.
• Some reserve coolant to the radiator to cover
minor leaks and evaporation or boiling losses.
REMOVAL
REMOVAL - COOLING FAN
(1) (Refer to 7 - COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - REMOVAL)
REMOVAL - COOLING FAN SUPPORT
(1) Disconnect negative battery cable.
(2) Remove fan drive viscous clutch and fan
assembly (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH - REMOVAL).
(3) Remove cooling fan support from engine block
(Fig. 1).
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
fan drive viscous clutch should also be inspected.
These components could have been damaged due
to excessive vibration.
7 - 18 ENGINE KJ
COOLING FAN (Continued)
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Disconnect upper radiator hose from thermostat housing (Fig. 2).
(3) Disconnect upper radiator hose from radiator
and remove from vehicle (Fig. 2).
Fig. 1 COOLING FAN SUPPORT
1 - IDLER PULLEY
2 - COOLING FAN SUPPORT
3 - RETAINING BOLTS
4 - ENGINE LIFT HOOK
(1) Remove fan blade assembly from fan drive vis-
cous clutch (four bolts).
(2) Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
INSTALLATION
INSTALLATION - COOLING FAN
(1) (Refer to 7 - COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - INSTALLATION)
INSTALLATION - COOLING FAN SUPPORT
(1) Install cooling fan support to engine block (Fig.
1). Torque bolts to 47.1N·m.
(2) Install fan drive viscous clutch and fan assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - INSTALLATION).
(3) Connect negative battery cable.
Fig. 2 UPPER RADIATOR HOSE
1 - FAN SHROUD
2 - HOSE CLAMP
3 - UPPER RADIATOR HOSE
4 - THERMOSTAT HOUSING
REMOVAL - HEATER CORE HOSES
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove engine cover from engine (Refer to 9 -
ENGINE COVER - REMOVAL).
(3) Disconnect heater core supply line at heater
core and viscous heater (Fig. 3). Remove hose from
vehicle.
(4) Disconnect heater core return line from heater
core and EGR cooler (Fig. 3). Remove hose from vehicle.
KJ ENGINE 7 - 19
COOLANT SYSTEM HOSES (Continued)
ENGINE COOLANT TEMP SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 4).
New sensors have sealant applied to the threads.
Fig. 3 HEATER CORE COOLANT HOSES
1 - HEATER CORE TO VISCOUS HEATER HOSE
2 - MOUNTING STUD
3 - HOSE CLAMP
4 - HOSE CLAMP
5 - HEATER CORE TO EGR COOLER HOSE
INSTALLATION
INSTALLATION - UPPER RADIATOR HOSE
(1) Install upper radiator hose on radiator and
thermostat housing (Fig. 2).
(2) Reposition hose clamps in proper position.
(3) Refill cooling system to proper level (Refer to 7
- COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
INSTALLATION – HEATER CORE HOSES
(1) Connect heater core supply hose to heater core
and viscous heater. Position hose clamps into proper
position.
(2) Connect heater core return hose to heater core
and EGR cooler. Position hose clamps into proper
position.
(3) Install engine cover to engine (Refer to 9 ENGINE COVER - INSTALLATION).
(4) Refill cooling system to proper level (Refer to 7
- COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
Fig. 4 CYLINDER HEAD ASSEMBLY
1 - CYLINDER HEAD BOLT
2 - GLOW PLUG
3 - COOLANT TEMPERATURE SENSOR
4 - CYLINDER HEAD ALIGNMENT DOWEL
5 - GLOW PLUG HARNESS
6 - CYLINDER LINER
7 - CYLINDER BLOCK
8 - CYLINDER HEAD GASKET
9 - CYLINDER HEAD
10 - ROCKER ARM ASSEMBLIES
OPERATION
The coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor (resistance varies inversley with temperature). This means
at cold tempertures its resistance is high so the voltage signal will be high. As coolant temperture
increases, resistance decreases and the signal voltage
will be low. This allows the sensor to provide an analog voltage signal to the ECM.
7 - 20 ENGINE KJ
ENGINE COOLANT TEMP SENSOR (Continued)
REMOVAL
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1) Disconnect negative battery cable.
(2) Drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)
(3) Disconnect coolant temperature sensor electrical connector (Fig. 5).
(4) Remove coolant temperature sensor from cylinder head (Fig. 5).
INSTALLATION
(1) Install coolant temperature sensor in cylinder
head (Fig. 5).
(2) Connect coolant temperature sensor electrical
connector (Fig. 5).
(3) Refill cooling system. (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE)
(4) Connect negative battery cable.
ENGINE COOLANT THERMOSTAT
DESCRIPTION
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator (Fig. 6).
OPERATION
The thermostat starts to open at 80°C (176°F).
Above this temperature, coolant is allowed to flow to
the radiator. This provides quicker engine warmup
and overall temperature control.
The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing.
Operating without a thermostat causes other problems. These are: longer engine warmup time, unreliable warmup performance, increased exhaust
emissions and crankcase condensation. This condensation can result in sludge formation.
Fig. 5 CYLINDER HEAD ASSEMBLY
1 - CYLINDER HEAD BOLT
2 - GLOW PLUG
3 - COOLANT TEMPERATURE SENSOR
4 - CYLINDER HEAD ALIGNMENT DOWEL
5 - GLOW PLUG HARNESS
6 - CYLINDER LINER
7 - CYLINDER BLOCK
8 - CYLINDER HEAD GASKET
9 - CYLINDER HEAD
10 - ROCKER ARM ASSEMBLIES
REMOVAL
NOTE: The thermostat is not serviced separately.
The thermostat and housing must be replaced as
an assembly.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Partially drain cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Disconnect upper radiator hose and bypass
hoses at thermostat housing.
(5) Remove thermostat housing retaining bolts,
support bracket (2.8L) and housing from cylinder
head, discard gasket (Fig. 7).
KJ ENGINE 7 - 21
ENGINE COOLANT THERMOSTAT (Continued)
Fig. 6 THERMOSTAT HOUSING
1 - THERMOSTAT HOUSING GASKET
2 - THERMOSTAT HOUSING
3 - TURBOCHARGER OIL SUPPLY LINE BANJO BOLT
4 - THERMOSTAT HOUSING RETAINING BOLTS
5 - BRASS WASHER
6 - EXHAUST MANIFOLD GASKET
7 - EXHAUST MANIFOLD
8 - EXHAUST MANIFOLD HEATSHIELD
9 - EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS
10 - OIL RETURN HOSE
11 - HOSE CLAMPS
12 - EXHAUST MANIFOLD RETAINING NUTS
13 - TURBOCHARGER DOWNPIPE STUDS
14 - TURBOCHARGER DOWN PIPE GASKET
15 - TURBOCHARGER DOWNPIPE
16 - TURBOCHARGER DOWNPIPE RETAINING NUT
INSTALLATION
(1) Clean old gasket material from cylinder head
and thermostat housing.
(2) Install thermostat housing with gasket and
support bracket (2.8L) to cylinder head (Fig. 7).
Torque bolts to 27.5N·m.
(3) Connect coolant bypass hose and upper radiator hose to thermostat housing.
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
Fig. 7 THERMOSTAT HOUSING ASSEMBLY
1 - THERMOSTAT HOUSING GASKET
2 - THERMOSTAT HOUSING
3 - RETAINING BOLTS
4 - CYLINDER HEAD
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
(5) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(6) Connect negative battery cable.
FAN DRIVE VISCOUS CLUTCH
DESCRIPTION
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
The thermal viscous fan drive (Fig. 8) is a siliconefluid-filled coupling used to connect the fan blades to
the fan support bracket assembly. The coupling
allows the fan to be driven in a normal manner. This
is done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
7 - 22 ENGINE KJ
FAN DRIVE VISCOUS CLUTCH (Continued)
On the 2.5L Diesel engine, a viscous fan is stan-
dard.
Fig. 8 Viscous Fan Drive - Typical
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
OPERATION
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit. This
spring coil reacts to the temperature of the radiator
discharge air. It engages the viscous fan drive for
higher fan speed if the air temperature from the
radiator rises above a certain point. Until additional
engine cooling is necessary, the fan will remain at
a reduced rpm regardless of engine speed. Normally less than three hundred (300) rpm.
Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing
through the radiator core causes a reaction to the
bimetallic coil. It then increases fan speed to provide
the necessary additional engine cooling.
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.
DIAGNOSIS AND TESTING - FAN DRIVE VISCOUS CLUTCH
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against excessively high coolant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Drill a 3.18-mm (1/8-in) diameter hole in the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
(or equivalent). It should have a range of -18° to
105°C (0° to 220° F). Insert thermometer through the
hole in the shroud. Be sure that there is adequate
clearance from the fan blades.
(3) Connect a tachometer and an engine ignition
timing light (timing light is to be used as a strobe
light).
(4) Block the air flow through the radiator. Secure
a sheet of plastic in front of the radiator (or air conditioner condenser). Use tape at the top to secure the
plastic and be sure that the air flow is blocked.
(5) Be sure that the air conditioner (if equipped) is
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engine and operate at 2400 rpm.
Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 93° C (200° F).
Fan drive engagement should have started to occur
at between 91° to 96° C (195° to 205° F). Engagement is distinguishable by a definite increase in fan
flow noise (roaring). The timing light also will indicate an increase in the speed of the fan.
(7) When the air temperature reaches 93° C (200°
F), remove the plastic sheet. Fan drive disengage-
ment should have started to occur at between 62° to
85° C (145° to 185° F). A definite decrease of fan
flow noise (roaring) should be noticed. If not, replace
the defective viscous fan drive unit.
REMOVAL
(1) Disconnect negative battery cable.
NOTE: The thermal viscous fan drive/fan blade
assembly is attached (threaded) to fan support.
(2) Remove fan blade/viscous fan drive assembly
from water pump using special tool 6958 spanner
wrench, by turning mounting nut counterclockwise
as viewed from front (Fig. 9) (Fig. 10). Threads on
viscous fan drive are RIGHT HAND.
(3) Do not attempt to remove fan/fan drive viscous
clutch assembly from vehicle at this time.
(4) Do not unbolt fan blade assembly from fan
drive viscous clutch at this time.
(5) Remove fan shroud to radiator bolts.
(6) Remove fan shroud and fan blade/fan drive viscous clutch assembly as a complete unit from vehicle.
KJ ENGINE 7 - 23
FAN DRIVE VISCOUS CLUTCH (Continued)
(7) After removing fan blade/fan drive viscous
clutch assembly, do not place viscous clutch in horizontal position. If stored horizontally, silicone fluid in
the fan drive viscous clutch could drain into its bearing assembly and contaminate lubricant.
(8) Remove four bolts securing fan blade assembly
to fan drive viscous clutch.
INSTALLATION
(1) Assemble fan blade to viscous fan drive.
Tighten mounting bolts to 27 N·m (20 ft. lbs.) torque.
NOTE: The viscous fan and fan shroud must be
installed as an assembly.
(2) Gently lay fan and viscous drive into fan
shroud.
(3) Install the fan shroud to radiator mounting
bolt. Torque bolts to 5.5N·m.
(4) Thread the fan and viscous drive onto the fan
support and tighten nut using special tool 6958 spanner wrench.
Fig. 9 FAN DRIVE VISCOUS CLUTCH - TYPICAL
1 - SPECIAL TOOL 6958 SPANNER WRENCH
2-FAN
(5) Connect negative battery cable.
RADIATOR
Fig. 10 COOLING FAN AND VISCOUS CLUTCH
1 - COOLING FAN AND FAN DRIVE VISCOUS CLUTCH
ASSEMBLY
2 - FAN SUPPORT
REMOVAL
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(3) Remove engine oil fill cap.
(4) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(5) Remove air filter assembly from the engine bay.
(6) Recover and evacuate the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(7) Disconnect high side refrigerant line from the
upper radiator support bracket.
(8) Remove upper radiator support bracket retaining bolts and remove the support bracket.
(9) Remove high side refrigerant line retaining nut
and remove the line from the condenser assembly.
Position the line out of the way.
(10) Unbolt cooling fan from cooling fan support.
(11) Remove fan shroud retaining bolts and
remove the fan and shroud as an assembly.
(12) Disconnect charge air cooler hoses from the
charge air cooler.
(13) Disconnect engine coolant hoses from the radiator.
(14) Disconnect coolant reservoir hose from the
radiator.
7 - 24 ENGINE KJ
RADIATOR (Continued)
(15) Remove low side refrigerant line retaining nut
and remove the line from the condenser assembly.
Position the line out of the way.
(16) Remove condenser assembly retaining bolts
and remove the condenser from the vehicle.
(17) Remove power steering cooler retaining bolts
and unclip the air deflectors from both sides of the
radiator (cooling module) assembly.
(18) Lift cooling module assembly out of the engine
bay.
(19) Remove radiator retaining bolts and remove
the cooling system module from vehicle.
(20) Separate charge air cooler from radiator.
INSTALLATION
(1) Install radiator on the charge air cooler and
install retaining bolts.
(2) Install radiator (cooling module) assembly in
the engine bay.
(3) Install power steering cooler retaining bolts
and clip the air deflectors on both sides of the radiator (cooling module) assembly.
(4) Install condenser assembly and retaining bolts.
(5) Install low side refrigerant line and retaining
nut.
(6) Connect coolant reservoir hose on the radiator.
(7) Connect engine coolant hoses on the radiator.
(8) Connect charge air cooler hoses on the charge
air cooler.
(9) Install fan and fan shroud assembly and
retaining bolts.
(10) Install cooling fan assembly to cooling fan
support.
(11) Install high side refrigerant line and retaining
nut.
(12) Install upper radiator support bracket and
retaining bolts.
(13) Connect high side refrigerant line on the
upper radiator support bracket.
(14) Evacuate and re-charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(15) Install air filter assembly in the engine bay.
(16) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(17) refill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(18) Connect negative battery cable.
WATER PUMP
DESCRIPTION
The water pump on the 2.5L/2.8L CRD diesel has a
die cast aluminum housing. It bolts to a aluminum
housing which attaches to the engine block.
OPERATION
The water pump is used to circulate coolant
through the cooling system. The coolant is pumped
through the engine block, cylinder head, heater core,
EGR cooler, viscous heater, and radiator.
REMOVAL - WATER PUMP
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove timing belt inner and outer covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Remove water pump retaining bolts and pump
(Fig. 11).
Fig. 11 WATER PUMP LOCATION
1 - CYLINDER HEAD
2 - ENGINE BLOCK
3 - OIL COOLER
4 - OIL FILTER HOUSING
5 - WATER PUMP
CLEANING
Clean gasket mating surfaces as necessary.
KJ ENGINE 7 - 25
WATER PUMP (Continued)
INSTALLATION
(1) Clean mating surfaces of water pump housing
and engine block as necessary.
(2) Place new o-ring in groove in water pump
housing. Install water pump and retaining bolts.
Torque bolts to 24.4N·m.
(3) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system pressure cap is located on the
coolant recovery pressure container. The cap construction includes; stainless steel swivel top, rubber
seals, and retainer, main spring, and a spring loaded
valve (Fig. 12).
through a connecting hose. If valve is stuck shut,
or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 12) and inspect coolant recovery hose routing, to ensure proper
sealing when boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.
If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant
and eventual overheating due to low coolant
level in radiator and engine.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM PRESSURE CAP
Dip the pressure cap in water. Clean any deposits
off the vent valve or its seat and apply cap to end of
the Pressure Cap Test Adaptor that is included with
the Cooling System Tester 7700. Working the
plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at
least 97 kPa (14 psi), replace the pressure cap.
Fig. 12 Cooling System Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - PRESSURE BOTTLE
8 - FILLER NECK
OPERATION
The cooling system is equipped with a pressure cap
that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radiator cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing the coolant to return to cooling
system from coolant reserve system tank by vacuum
CAUTION: The Cooling System Tester Tool is very
sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not
have a history 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.
If the pressure cap tests properly while positioned
on Cooling System Tester (Fig. 13), but will not hold
pressure or vacuum when positioned on the filler
neck. Inspect the filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
DIAGNOSIS AND TESTING - PRESSURE RELIEF TEST
The pressure cap upper gasket (seal) pressure
relief can be checked by removing the overflow hose
at the radiator filler neck nipple (Fig. 14). Attach the
Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at 55 kPa (8 psi) minimum.
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