Engine Cooling System & Automatic Transmission Cooling System: Removal & Installation Chrysler Pacifica CS

INSTALLATION

1. Install the belt tensioner and bolt. Tighten bolt to 28 N.m (250 in. lbs.).
2. Install the drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-245448-S15036353902006110200000) .
3. Install the drive belt shield.
4. Lower the vehicle.

REMOVAL

1. Remove the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(ref-245448-S38168346922006110200000).
2. Remove the bolt and the upper idler pulley.
3. Remove the bolt and the lower idler pulley. (Scheme 29)

Scheme 29

1. Install bolt and lower idler pulley.
2. Install bolt and upper idler pulley
3. Install the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(ref-245448-S15036353902006110200000) .

1. Disconnect two recovery hoses from the coolant recovery container. (Scheme 30)
2. Remove the lower attaching nuts. (Scheme 30)
3. Remove the upper attaching nut. (Scheme 30)
4. Remove the recovery container.

Scheme 30

1. Connect the recovery hose to container.
2. Position the recovery container on the frame rail. (Scheme 30)
3. Install the upper attaching screw and tighten to 7 N.m (60 in. lbs.).
4. Raise the vehicle on hoist.
5. Install the lower attaching screws and tighten to 8.5 N.m (75 in. lbs.).
6. Lower the vehicle.
7. Add coolant to container as necessary «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).

There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as an assembly. (Scheme 31)

1. Remove the front fascia «FRONT FASCIA»(ref-245440-S14371693552006110200000).
2. Disconnect the radiator fan electrical connectors.
3. Remove radiator fan(s) retaining screw. (Scheme 31)
4. Remove the radiator fan(s) by lifting upward to release from mounts.

Scheme 31

1. Install the radiator fan(s) into mounts and attaching clips on the radiator.
2. Install radiator fan(s) attaching screws. (Scheme 31) Tighten to 5 N.m (45 in. lbs.).
3. Connect the radiator fan(s) electrical connectors.
4. Install the front fascia «FRONT FASCIA»(ref-245440-S14371693552006110200000).
5. Install the upper radiator mounts to the crossmember bolts, if removed. Tighten to 8 N.m (70 in. lbs.).

1. Drain coolant from radiator and cylinder block «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
2. Disconnect the power cord plug from heater.
3. Loosen bolt. Remove the block heater assembly. (Scheme 32)

Scheme 32

1. Clean block core hole and heater seat.
2. Insert heater assembly with element loop positioned upward.
3. With heater seated, tighten center screw securely to assure a positive seal.
4. Install power cord plug to heater.
5. Fill cooling system with coolant to the proper level. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000) .

1. Drain cooling system below engine coolant temperature sensor level «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
2. Disconnect negative cable from remote jumper terminal. see scheme 20
3. With the engine cold, disconnect coolant sensor electrical connector.
4. Remove sensor.

1. Install engine coolant temperature sensor. see scheme 20 Tighten sensor to 7 N.m (60 in. lbs.).
2. Connect electrical connector to sensor.
3. Fill cooling system. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000)

REMOVAL - 3.5L

Scheme 33

1. Disconnect negative cable from remote jumper terminal.
2. Drain cooling system. Refer to «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
3. Disconnect radiator upper hose from thermostat housing.
4. Remove thermostat housing bolts. (Scheme 33)
5. Remove housing, thermostat, and gasket. 1 - THERMOSTAT HOUSING/COOLANT INLET 2 - BOLTS

Scheme 34

1. Drain cooling system below the thermostat level. Refer to «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
2. Remove radiator upper hose from coolant outlet connector.
3. Remove coolant outlet connector bolts and connector. (Scheme 34)
4. Remove thermostat from outlet connector.
5. Discard gasket and clean both gasket sealing surfaces. 1 - THERMOSTAT HOUSING/COOLANT INLET 2 - BOLTS 3 - THERMOSTAT 4 - GASKET

INSTALLATION - 3.5L

1. Clean gasket sealing surfaces.
2. Install thermostat and gasket into thermostat housing. For ease of installation, install bolts in housing for thermostat and gasket retention.
3. Install thermostat and housing to intake manifold. (Scheme 33) Tighten bolts to 12 N.m (105 in. lbs.).
4. Connect radiator hose and install hose clamps.
5. Refill cooling system. Refer to «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
6. Connect negative cable to remote jumper terminal.

Scheme 35

Scheme 36

1. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place. (Scheme 35) It is not necessary to restake the replacement thermostat into the connector. 1 - STAKE 2 - OUTLET CONNECTOR
2. Position thermostat to coolant outlet connector. Align the two locating notches on thermostat to the connector. This position will ensure proper location of the thermostat air bleed. 1 - LOCATING NOTCHES 2 - THERMOSTAT 3 - COOLANT OUTLET CONNECTOR
3. Position a new gasket over the thermostat and connector making sure thermostat is in proper position and in the recess provided.
4. Install thermostat and connector assembly to the intake manifold. Tighten bolts to 28 N.m (250 in. lbs.).
5. Install the radiator upper hose to coolant outlet connector.
6. Refill the cooling system to the proper level. Refer to «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).

1. Drain cooling system. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
2. Remove upper and lower intake manifold (Refer to «INTAKE MANIFOLD»(ref-245454-S15097980062006110200000) - 3.5L or «INTAKE MANIFOLD - UPPER»(ref-245455-S32765950852006110200000) and «INTAKE MANIFOLD - LOWER»(ref-245455-S24570546002006110200000) - 3.8L).
3. Position lower intake manifold upside down on bench and remove the tube retaining bolt. (Scheme 37)
4. Remove tube from manifold and discard O-ring.

Scheme 37

1. Clean heater tube sealing surfaces.
2. Inspect heater tube O-ring. Replace as necessary.
3. Lubricate O-ring with a silicone type grease such as Mopar® Dielectric Grease. (Scheme 37)
4. Install O-ring on heater tube.
5. Install heater tube on manifold.
6. Install retaining bolts and tighten to 12 N.m (105 in. lbs.).
7. Install lower and upper intake manifolds (Refer to «INTAKE MANIFOLD»(ref-245454-S15097980062006110200000) - 3.5L or «INTAKE MANIFOLD - UPPER»(ref-245455-S32765950852006110200000) and «INTAKE MANIFOLD - LOWER»(ref-245455-S24570546002006110200000) - 3.8L).
8. Refill cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).

1. Install A/C condenser, (if removed) «A/C CONDENSER»(ref-245452-S17903156682006110200000) .
2. Install radiator fan assemble, if removed «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(ref-245448-S13225941362006110200000) .
3. Install auxiliary transmission cooler, if removed.
4. Slide radiator down into position. Seat the radiator with the rubber isolators into the mounting holes provided, with a 10 lbs. force.
5. Install mounting screws.
6. Connect the cooling fan electrical connector.
7. Install the radiator upper and lower hoses
8. In the LH and RH radiator seals.
9. Install the upper radiator seal.
10. Install the auxiliary transmission cooler hoses.
11. Connect the coolant reserve/recovery hose.
12. Install the front fascia «FRONT FASCIA»(ref-245440-S14371693552006110200000) .
13. Fill the cooling system. «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000) .
14. Connect negative cable to battery.

1. Drain the cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000).
2. Turn the draincock stem counterclockwise 180 degrees to the 9:00 o'clock position.
3. With the stem at the 9:00 o'clock position, pull the draincock assembly from the radiator tank. (Scheme 38)

Scheme 38

1. Inspect the draincock body and O-ring for damage. Replace as necessary.
2. Position the draincock assembly horizontally to the tank opening with the manufactures identification mark facing down.
3. Push the draincock assembly into the tank opening while rotating clockwise until it snaps into place.
4. Close the draincock stem by turning clockwise until it stops at the horizontal position.
5. Fill the cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000) .

1. Open hood.
2. Disconnect and isolate the battery negative cable.
3. Practically remove the front fascia to gain access to the radiator fan relay «(Refer to BODY/EXTERIOR/GRILLE - REMOVAL)»(ref-245423-S15269820532006110200000).
4. Disconnect the relay electrical connector. (Scheme 39)
5. Remove the rivet attaching the relay to the front bumper beam. (Scheme 39)
6. Remove the relay.

Scheme 39

1. Position relay and install a new rivet. (Scheme 39)
2. Connect electrical connector to relay.
3. Install front fascia «(Refer to BODY/EXTERIOR/GRILLE - INSTALLATION)»(ref-245423-S07540243912006110200000).
4. Connect negative cable to battery.

The water pump on all models can be replaced without discharging the air conditioning system.

Note. It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump.

1. Drain cooling system «(Refer to COOLING - STANDARD PROCEDURE)»(ref-245448-S20805593812006110200000). NOTE: The water pump is driven by the timing belt.
2. Remove engine timing belt (Refer to «TIMING CHAIN AND SPROCKETS»(ref-245455-S16803643932006110200000) ).
3. Remove water pump mounting bolts. (Scheme 40) Note position of longer bolt for proper re-installation.
4. Remove water pump body from engine. (Scheme 40)

Scheme 40

1. Remove the upper radiator closure panel «(Refer to BODY/EXTERIOR/CLOSURE PANEL - REMOVAL)»(ref-245423-S07656765742006110200000) .
2. Disconnect lines from oil cooler «(Refer to COOLING/TRANSMISSION - STANDARD PROCEDURE)»(ref-245448-S25985554072006110200000) .
3. Remove oil cooler attaching screws.
4. Remove the oil cooler.

1. Position the transmission cooler on the radiator and install the mounting bolts. Tighten to 5 N.m (45 in. lbs.)
2. Connect the cooler hoses to the transmission cooler «(Refer to COOLING/TRANSMISSION - STANDARD PROCEDURE)»(ref-245448-S25985554072006110200000) .
3. Install the cowl plenum grille «(Refer to BODY/EXTERIOR/COWL GRILLE - INSTALLATION)»(ref-245423-S24731900242006110200000) .
4. Start engine and check transmission oil level. Adjust level as necessary.