Engine Cooling System: Other — Dodge Avenger II рестайлинг (2011-2014)

COOLING SYSTEM FLOW - 2.4L

1 - WATER PUMP
2 - RETURN TUBE
3 - WATER PLENUM
4 - PRIMARY THERMOSTAT
5 - TRANSMISSION
6 - INTERNAL TRANSMISSION COOLER
7 - COMBINATION COOLER
8 - RADIATOR
9 - SECONDARY THERMOSTAT
10 - CYLINDER BLOCK
11 - CYLINDER HEAD
12 - HEATER CORE

The primary purpose of a cooling system is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions.

Scheme 29

Scheme 29: COOLING FLOW - 3.6L PHOENIX

1 - RADIATOR
2 - RH CYLINDER HEAD
3 - THERMOSTAT
4 - WATER CROSSOVER
5 - LH CYLINDER HEAD
6 - REAR HEATER CORE
7 - FRONT HEATER CORE
8 - OIL COOLER
9 - WATER PUMP
10 - CRANKCASE

The cooling system also provides hot water (coolant) for heater performance.

TRAILER TOWING

Consult Trailer Towing 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).

Note. If investigation reveals none of the previous items as a cause for an engine overheating complaint, refer to the COOLING SYSTEM DIAGNOSIS CHART below.

These charts are to be used as a quick-reference only.

CONDITION	POSSIBLE CAUSE	CORRECTION
TEMPERATURE GAUGE READS LOW	1. Diagnostic Trouble Code (DTC) set indicating a stuck open engine thermostat.	1. (Refer to Appropriate Diagnostic Information) Replace thermostat, if necessary. If a (DTC) has not been set, the problem may be with the temperature gauge.
	2. Problem with Engine Coolant Temperature (ECT) sensor or circuit.	2. Refer to the Appropriate Diagnostic Information for checking the ECT sensor
	3. Problem with temperature gauge.	3. Check Gauge operation. (Refer to the Appropriate Diagnostic Information)
	4. Coolant level low during cold ambient temperature, accompanied by poor heater performance.	4. Check coolant level. Inspect the system for leaks. Refer to DIAGNOSIS AND TESTING . Repair as necessary.
TEMPERATURE GAUGE READS HIGH OR ENGINE COOLANT WARNING LAMP ILLUMINATES. COOLANT MAY OR MAY NOT BE LOST FROM SYSTEM.	1. Trailer being towed, a steep hill being climbed, vehicle being operated in slow moving traffic, or engine idling during high ambient (outside) temperatures with A/C on. High altitudes could cause these conditions.	1. This may be a temporary condition and repair not necessary. Turn off A/C and drive vehicle. Observe temperature gauge. Gauge should return to normal range. If not, determine cause of overheating and repair. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for POSSIBLE CAUSES .
	2. Is temperature gauge (if equipped) reading correctly?	2. Check gauge (Refer to the Appropriate Diagnostic Information). Repair as necessary.
	3. Is temperature warning lamp (if equipped) illuminating unnecessarily?	3. Check warning lamp operation (Refer to Appropriate Diagnostic Information). Repair as necessary.
	4. Low coolant level.	4. Check for coolant leaks. Refer to DIAGNOSIS AND TESTING . Repair as necessary.
	5. Pressure cap not installed tightly. If cap is loose, boiling point of coolant will be lowered.	5. Tighten pressure cap.
	6. Poor seals at pressure cap.	6. (a) Check condition of cap and cap seals. Refer to CAP, RADIATOR, INSPECTION . Replace cap if necessary.
	6. Poor seals at pressure cap.	(b) Check condition of filler neck. If neck is damaged, replace as necessary.
	7. Wrong pressure cap installed.	7. Verify proper pressure cap part number.
	8. 2.0L/2.4L Vehicles: Coolant level low in radiator, but not in coolant recovery container. This indicates radiator is not drawing coolant from coolant recovery container as the engine cools. As engine cools, a vacuum is formed inside cooling system. If radiator cap seals are defective, or cooling system has a leak, a vacuum cannot be formed.	8. (a) Check condition of pressure cap and seals. Replace cap if necessary.
		(b) Check condition of filler neck. Replace if damaged.
		(c) Check condition of hose from filler neck to coolant container. It should be tight at both ends without any kinks or tears. Replace hose as necessary.
		(d) Check coolant recovery container and hose for blockage. Repair as necessary.
TEMPERATURE GAUGE READS HIGH OR ENGINE COOLANT WARNING LAMP ILLUMINATES. COOLANT MAY OR MAY NOT BE LOST FROM SYSTEM, continued.	9. Freeze point of coolant not correct. Mixture ratio may be too rich.	9. Check coolant concentration. Adjust glycol-to-water ratio as required. Refer to COOLANT, DIAGNOSIS AND TESTING .
	10. Coolant not flowing through system.	10. (a) 2.0L/2.4L Vehicles: Check for coolant flow at filler neck with some coolant removed, engine warm and thermostat open. Coolant should be observed flowing through filler neck. If flow is not observed, determine reason for lack of flow and repair as necessary.
	10. Coolant not flowing through system.	(b) 3.6L Vehicles: Engine coolant motion should be observable in coolant pressure container when revving the engine while running.
	11. Radiator or A/C condenser fins dirty or clogged.	11. Clean obstruction from fins.
	12. Radiator core is plugged or corroded.	12. Clean or replace radiator as necessary.
	13. Fuel or ignition system problems.	13. Refer to Appropriate Diagnostic Information.
	14. Dragging Brakes.	14. Inspect brake system and repair as necessary (Refer to BRAKE NOISE ).
	15. Bug screen or other aftermarket accessory causing reduced air flow.	15. Remove bug screen or accessory.
	16. Thermostat partially or completely closed.	16. Check thermostat and replace as necessary. Refer to THERMOSTAT, DIAGNOSIS AND TESTING .
	17. Electric radiator fan not operating properly.	17. Check electric fan operation and repair as necessary.
	18. Cylinder head gasket leaking.	18. Check cylinder head gasket for leaks. Refer to DIAGNOSIS AND TESTING or DIAGNOSIS AND TESTING .
	19. Heater core leaking.	19. Check heater core for leaks. Repair as necessary.
TEMPERATURE GAUGE READING IS INCONSISTENT (FLUCTUATES, CYCLES OR IS ERRATIC)	1. The gauge may cycle up and down. This is due to the cycling of the electric radiator fan and/or changing vehicle operating conditions.	1. A normal condition. No correction is necessary. If gauge cycling is going into the hot zone, check electric fan operation and repair as necessary.
	2. During cold weather operation with the heater blower in the high position, the gauge reading may drop slightly.	2. A normal condition. No correction is necessary.
	3. Temperature gauge or engine coolant temperature sensor is defective or shorted.	3. Check operation of gauge and repair as necessary. (Refer to the Appropriate Diagnostic Information)
	4. Gauge reading rises when vehicle is brought to a stop after heavy use (engine still running).	4. A normal condition. No correction is necessary. The gauge should return to normal range after vehicle is driven.
	5. Gauge reading high after restarting a warmed-up (hot) engine.	5. A normal condition. No correction is necessary. The gauge should return to normal range after a few minutes of engine operation.
	6. Coolant level low (air will build up in the cooling system causing the thermostat to open late).	6. Check cooling system for leaks. Refer to DIAGNOSIS AND TESTING . Repair as necessary.
	7. Cylinder head gasket leaking allowing exhaust gas to enter cooling system. This will cause thermostat to open late.	7. (a) Check for cylinder head gasket leaks. Repair as necessary. Refer to DIAGNOSIS AND TESTING or DIAGNOSIS AND TESTING .
		(b) Check for coolant in the engine oil. Inspect for white steam emitting from exhaust system. Repair as necessary.
	8. Water pump impeller or pulley loose on shaft.	8. Check water pump and replace as necessary.
	9. Air leak on the suction side of water pump allows air to build up in cooling system. This will cause the thermostat to open late.	9. Locate leak and repair as necessary.
PRESSURE CAP IS BLOWING OFF STEAM AND/OR COOLANT FLOWING INTO RECOVERY CONTAINER. TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL, BUT NOT HIGH. COOLANT LEVEL MAY BE HIGH IN RECOVERY CONTAINER.	1. Pressure relief valve in pressure cap defective or wrong pressure cap installed.	1. Verify proper pressure cap part number. Check condition of pressure cap and seals. Replace as necessary. Refer to CAP, RADIATOR, DIAGNOSIS AND TESTING .
	2. Cooling system over filled.	2. Drain cooling system to proper level.
COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF. GAUGE IS READING HIGH OR HOT.	1. Coolant leaks in radiator, cooling system hoses, water pump or engine.	1. Pressure test and repair as necessary. Refer to DIAGNOSIS AND TESTING .
DETONATION OR PRE-IGNITION (NOT CAUSED BY IGNITION SYSTEM). GAUGE MAY OR MAY NOT BE READING HIGH.	1. Engine overheating.	1. Check reason for overheating and repair as necessary.
	2. Freeze point of coolant not correct.	2. Check the freeze point of the coolant. Refer to COOLANT, DIAGNOSIS AND TESTING .
	3. Coolant level low.	3. Fill cooling system to proper level.
HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING	1. Vacuum created in cooling system on engine cool-down is not being relieved through coolant recovery container system.	1. (a) Radiator pressure cap relief valve stuck. Refer to CAP, RADIATOR, DIAGNOSIS AND TESTING . Replace as necessary.
		(b) Hose between coolant recovery container and radiator is kinked. Repair as necessary.
		(c) Vent at coolant recovery container is plugged. Clean vent and repair as necessary.
		(d) Coolant recovery container is internally blocked or plugged. Check for blockage and repair as necessary.
ELECTRIC RADIATOR FAN OPERATES ALL THE TIME.	1. Fan relay, Powertrain Control Module (PCM) or engine coolant temperature sensor defective.	1. (Refer to the Appropriate Diagnostic Information) Repair as necessary.
	2. Check for low coolant level.	2. Repair as necessary. Refer to STANDARD PROCEDURE .
	3. Defective transmission temperature sensor.	3. Check for transmission related diagnostic trouble codes. Refer to DIAGNOSIS AND TESTING for 41TE Transmission Diagnostics.
	4. Defective A/C pressure transducer.	4. Refer to Appropriate Diagnostic Information for any related trouble codes.
ELECTRIC RADIATOR FAN WILL NOT OPERATE. GAUGE READING HIGH OR HOT	1. Radiator fan motor defective.	1. Refer to the Appropriate Diagnostic Information. Repair as necessary.
	2. Radiator fan relay, Powertrain Control Module (PCM) or engine coolant temperature sensor defective.	2. Refer to the Appropriate Diagnostic Information. Repair as necessary.
	3. Blown fuse in Power Distribution Center (PDC).	3. Determine reason for blown fuse and repair as necessary.
NOISY FAN	1. Radiator fan blade loose.	1. Replace fan assembly.
	2. Radiator fan blade striking a surrounding object.	2. Locate point of fan blade contact and repair as necessary.
	3. Air obstructions at radiator or A/C condenser.	3. Remove obstructions and/or clean debris from radiator and/or A/C condenser.
	4. Radiator fan motor defective.	4. Replace as necessary. Refer to FAN, COOLING, REMOVAL .
INADEQUATE AIR CONDITIONER PERFORMANCE (COOLING SYSTEM SUSPECTED)	1. Radiator and/or air conditioning condenser is restricted, obstructed or dirty.	1. Remove restriction and/or clean as necessary.
	2. Electric radiator fan not operating when A/C is on.	2. Refer to the Appropriate Diagnostic Information. Repair as necessary.
	3. Engine is overheating (heat may be transferred from radiator to A/C condenser). High under hood temperature due to engine overheating may also transfer heat to A/C components.	3. Correct overheating condition.
INADEQUATE HEATER PERFORMANCE.	1. Has a Diagnostic Trouble Code (DTC) been set?	1. Refer to the Appropriate Diagnostic Information.
	2. Coolant level low.	2. Repair as necessary.
	3. Obstructions in heater hose fittings at engine.	3. Remove heater hoses at both ends and check for obstructions. Repair as necessary.
	4. Heater hose kinked.	4. Locate kinked area and repair as necessary.
	5. Water pump is not pumping coolant to heater core. When the engine is fully warmed up, both heater hoses should be hot to the touch.	5. Refer to PUMP, WATER, DIAGNOSIS AND TESTING . Repair as necessary.
HEAT ODOR	1. Various heat shields are used at certain driveline components. One or more of these shields may be missing.	1. Locate missing shields and replace or repair as necessary.
	2. Is temperature gauge reading above the normal range?	2. Refer to the previous Temperature Gauge Reads High in these Diagnostic Charts. Repair as necessary.
	3. Radiator fan operating incorrectly.	3. Repair as necessary. Refer to FAN, COOLING, DIAGNOSIS AND TESTING .
	4. Has undercoating been applied to any unnecessary component?	4. Clean undercoating as necessary.
	5. Engine may be running rich causing the catalytic converter to overheat.	5. Refer to the Appropriate Diagnostic Information. Repair as necessary.
POOR DRIVEABILITY (THERMOSTAT POSSIBLY STUCK OPEN). GAUGE MAY BE READING LOW	1. For proper driveability, good vehicle emissions and for preventing build-up of engine oil sludge, the thermostat must be operating properly. Has a Diagnostic Trouble Code (DTC) been set?	1. Refer to the Appropriate Diagnostic Information. Replace thermostat if necessary.
STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET, ENGINE IS WARMED UP, RUNNING, AND VEHICLE IS STATIONARY. TEMPERATURE GAUGE IS IN NORMAL RANGE.	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 contact the hot radiator, steam may be emitted. This usually occurs in cold weather with no fan or airflow to blow it away.	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.	1. Check the freeze point of the coolant. Refer to COOLANT, DIAGNOSIS AND TESTING .
COOLANT LEVEL CHANGES IN COOLANT RECOVERY CONTAINER	1. Level changes are to be expected as coolant volume fluctuates with engine temperature. If the level in the container was between the MIN and MAX marks when the engine was cold, the level should return to within that range after operation at elevated temperatures.	1. A normal condition. No repair is necessary.

COOLING SYSTEM DIAGNOSIS CHART

FLOW CHECK

To determine whether coolant is flowing through the cooling system, use one of the following procedures

PREFERRED METHOD

WARNING

Do not remove the cooling system pressure cap or any hose with the system hot and under pressure because serious burns from coolant can occur.

2.0L/2.4L: Remove pressure cap when engine is cold. Remove small amount of coolant. Idle engine until thermostat opens. You should observe coolant flow while looking down the filler neck. Once flow is detected install the pressure cap. Replace removed coolant into coolant recovery container.
2.7L/3.5L/2.0L Diesel: Start engine, coolant flow should be observable in coolant pressure container when revving the engine.

ALTERNATIVE METHOD

If engine is cold, idle engine until normal operating temperature is reached. Feel the upper radiator hose. If it is hot, coolant is circulating.

Scheme 30

Scheme 30: ULTRAVIOLET LIGHT METHOD

1 - TYPICAL BLACK LIGHT TOOL

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 engine until radiator upper hose is warm to touch. Aim the commercially available black light tool at components to be checked. If leaks are present, black light will cause additive to glow a bright green color.

The black light (1) can be used in conjunction with a pressure tester to determine if any external leaks exist.

PRESSURE TESTER METHOD

The engine should be at normal operating temperature. Recheck the system cold if cause of coolant loss is not located during the warm engine examination.

WARNING

Hot, pressurized coolant can cause injury by scalding.

Carefully remove radiator pressure cap from pressure bottle and check coolant level. Push down on cap to disengage it from stop tabs. Wipe inside of filler neck and examine lower inside sealing seat for nicks, cracks, paint, and dirt. Inspect radiator-to- reserve/overflow tank hose for internal obstructions. Insert a wire through the hose to be sure it is not obstructed.

Inspect cams on outside of filler neck. If cams are damaged, seating of pressure cap valve and tester seal will be affected.

Attach pressure tester ((special tool #7700, Tester, Cooling System) or an equivalent) to radiator filler neck.

Operate tester pump (1) to apply 110 kPa (16 psi) pressure to system. If hoses enlarge excessively or bulges while testing, replace as necessary. Observe gauge pointer and determine condition of cooling system according to following criteria

Holds Steady: If 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.

Drops Slowly: Indicates a small leak or seepage is occurring. Examine all connections for seepage or slight leakage with a flashlight. Inspect radiator, hoses, gasket edges and heater. Seal small leak holes with a Sealer Lubricant (or equivalent). Repair leak holes and inspect system again with pressure applied.

Drops Quickly: Indicates that serious leakage is occurring. Examine 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.

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.
Water pump seal may run dry, increasing the risk of premature seal failure.
Combustion gas leaks into the coolant can also cause the above problems.

2.4L

Removal of air from the engine cooling system only occurs when the engine is first warming up. Air in the cooling system will collect under the cooling system pressure cap while the engine is run and will be pushed into the coolant recovery container. When the engine cools down, coolant will be drawn from the coolant recovery container back into the active cooling system. Once the thermostat opens, deaeration no longer occurs. Multiple warm up and cool down cycles may be required to remove all the air in the cooling system. If the system is very low on coolant, deaeration will not occur. Following the proper cooling system fill procedure is essential for proper operation. This system will not function if the wrong cooling system pressure cap is installed. Ensure proper cooling system pressure cap is used. Verify proper pressure cap part number.

3.6L/2.0L DIESEL

This engine has a pressure system to remove air from the engine cooling system. Removal of air from the engine cooling system occurs continuously when the engine is run at speeds above idle. Thirty minutes of normal driving after a properly completed service fill will deaerate the engine cooling system. This system will not function if the wrong cooling system pressure cap is installed. Ensure proper cooling system pressure cap is used. Verify proper pressure cap part number.

Scheme 31

Scheme 31: COOLANT LEVEL CHECK - ROUTINE

1 - COOLANT RECOVERY CONTAINER CAP
2 - COOLANT RECOVERY CONTAINER
3 - MIN FILL LINE
4 - MAX FILL LINE

Note. Do not remove pressure cap for routine coolant level inspections.

Scheme 32

1 - COOLANT PRESSURE CONTAINER
2 - COOLANT PRESSURE CAP
3 - ENGINE OIL FILL
4 - ENGINE OIL DIPSTICK

The coolant bottle provides a quick visual method for determining the coolant level without removing the pressure cap. With the engine cold and not running , simply observe the level of the coolant in the coolant recovery container or the coolant pressure container.

The level should be between the MIN and MAX marks.

ADDING ADDITIONAL COOLANT

Note. 2.0L/2.4L - The pressure cap should only be removed if the coolant recovery container is empty.

When additional coolant is needed, it should be added to the coolant recovery container (2.0L/2.4L)/pressurized coolant recovery container (3.6L/2.0L Diesel).

for the proper type of coolant. Refer to CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION .

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.

CHEMICAL CLEANING

In some instances, use a radiator cleaner (Mopar® 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.

Scheme 33

Scheme 33: STANDARD PROCEDURE - COOLANT AIR EVACUATION

Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components.

Note. To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system.

WARNING

ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT.

WARNING

WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE.

Note. The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system.

Note. For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor).

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps.
Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank.
Attach the adapter cone (2) to the vacuum gauge (1).
Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1).
Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly.
Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum.
Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse.
Close the vacuum generator/venturi ball valve.
Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly.
Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated.
Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system.
Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2).
Open the suction hose's ball valve to begin refilling the cooling system.
When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached.
Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly.
Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank.
With heater control unit in the HEAT position, operate engine with container cap in place.
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 pressure container.
Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period.
Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap.

3.6L

Remove main drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
Lower vehicle.
Remove the air intake system.
Remove the mounting bolt holding the idler pulley (2).

Disconnect the negative battery cable.
Remove the air intake system. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485475-S36552825552012071300000) or «BODY, AIR CLEANER, REMOVAL»(ref-485476-S11662508332012071300000) .
Remove main drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
Remove tensioner assembly from engine front cover.

WARNING

Because of high spring tension, do not attempt to disassemble automatic tensioner. Unit is serviced as an assembly (except for pulley on tensioner).

Scheme 38

Scheme 38: 2.4L

1 - POWER STEERING PUMP
2 - ACCESSORY DRIVE BELT
3 - GENERATOR
4 - CRANKSHAFT PULLEY
5 - LOWER IDLER PULLEY
6 - CRANKSHAFT PULLEY
7 - WATER PUMP PULLEY
8 - ACCESSORY DRIVE BELT TENSIONER
9 - UPPER IDLER PULLEY

Position accessory drive belt tensioner (8) and install mounting bolt (1). Tighten bolt (1) to 24 N.m (212 in. lbs.).
Install accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
Install belt splash shield
Lower vehicle.

An indexing slot is located on back of tensioner. Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt to 41 N.m (30 ft. lbs.).
Install main drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
Check belt indexing marks.
Install the air intake system. Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-485475-S14868414802012071300000) or «BODY, AIR CLEANER, INSTALLATION»(ref-485476-S11483727402012071300000) .
Connect the negative battery.

Scheme 39

Scheme 39: NON-PRESURE SYSTEM

1 - BOLT
2 - RADIATOR NIPPLE
3 - HOSE
4 - COOLANT RECOVERY CONTAINER - NON-PRESSURE

The coolant recovery system consists of a container and an overflow hose that is connected to the coolant outlet connector. The coolant recovery container is mounted in the right side engine compartment.

Scheme 40

Scheme 40: PRESSURE SYSTEM

The coolant pressure container consists of a pressure chamber and an overflow chamber. The coolant pressure container is mounted in the right side engine compartment. An overflow hose connects the pressure chamber to the overflow chamber.

Note. Coolant will normally be in the pressure chamber side of the coolant bottle. The overflow chamber should normally be empty

Scheme 41

Scheme 41: NON-PRESSURE SYSTEM

1 - BOLT
2 - RADIATOR NIPPLE
3 - HOSE
4 - COOLANT RECOVERY CONTAINER - NON-PRESSURE

This system works in conjunction with the pressure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air. It provides a volume for expansion and contraction, provides a convenient and safe method for checking coolant level, and adjusting level at atmospheric pressure without removing the pressure cap. It also provides some reserve coolant to cover minor leaks and evaporation or boiling losses.

Scheme 42

Scheme 42: PRESSURE SYSTEM

1 - MOUNTING BOLT
2 - HOSE
3 - HOSE
4 - COOLANT RECOVER CONTAINER

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.

NON-PRESSURE SYSTEM

1 - BOLT
2 - RADIATOR NIPPLE
3 - HOSE
4 - COOLANT RECOVERY CONTAINER - NON-PRESSURE

Disconnect the overflow hose (3) from radiator nipple (2).
Remove coolant recovery container mounting bolts (1).
Remove coolant recovery container (4).

PRESSURE SYSTEM

Drain coolant below the coolant recovery container level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Remove the power steering reservoir attaching screw.
Disconnect the return hose (2) from coolant recover container (4).
Remove coolant recovery container mounting bolts (1).
Disconnect hose (3) from the bottom of the coolant recovery container (4).
Remove coolant recovery container (4).

1 - BOLT
2 - RADIATOR NIPPLE
3 - HOSE
4 - COOLANT RECOVERY CONTAINER - NON-PRESSURE

Connect the overflow hose (4) to the radiator nipple (2).
Install container in mounting position and install mounting bolts (1).
Tighten mounting bolts to 10 N.m (89 in. lbs.).
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Connect hose (3) to coolant recovery container (4).
Install coolant recovery container (4) in mounting position and install mounting bolts (1) Tighten bolts to 10 N.m (89 in. lbs.).
Connect return hose (2) to the coolant recovery container (4).
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 43

Scheme 43: DESCRIPTION

1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - COOLANT OUTLET CONNECTOR (2.0L/2.4L)/PRESSURE CONTAINER (2.7L)
8 - FILLER NECK

CAUTION

Vehicles equipped with 2.4L engines use a different pressure cap than vehicles equipped with 3.6L engines. The pressure caps are NOT interchangeable. Verify proper pressure cap part number.

The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97-124 kPa (14-18 psi).

There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant reserve/recovery system container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached.

Scheme 44

Scheme 44: RADIATOR PRESSURE CAP TESTING

1 - PRESSURE CAP
2 - PRESSURE TESTER

CAUTION

Vehicles equipped with 2.4L engines use a different pressure cap than vehicles equipped with 3.6L engines. The pressure caps are NOT interchangeable. Verify proper pressure cap part number.

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 (special tool #7700, Tester, Cooling System). 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.

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 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.

GAS ENGINES AND DIESEL ENGINES

WARNING

Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result.

CAUTION

Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection.

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar® Antifreeze/Coolant, 5 Year/100, 000 Mile Formula (MS-9769), or the equivalent ethylene glycol based coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 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.

The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant.

CAUTION

Mopar® Antifreeze/Coolant, 5 Year/100, 000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible.

RADIATOR FAN CONTROL

Fan control is accomplished three ways. The fan runs when the air conditioning pressure reaches a set pressure, refer to RADIATOR FAN OPERATION chart. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the Powertrain Control Module (PCM). The PCM turns on the fan through a fan relay. On models equipped with automatic transmission, a transmission fluid thermister may have some influences on fan operation. See appropriate Wiring Diagrams Information for circuity and diagnostics provided.

The Powertrain Control Module (PCM) provides fan control for the following conditions

The fan will not run during cranking until the engine starts no matter what the coolant temperature is.
Fan will run when the air conditioning clutch is engaged, and once set compressor head pressure is reached. See charts.
Fan will run according to the following information charts.

Radiator Fan Control			A/C Pressure
A/C Off	Low	High	N/A	N/A
Fan On	104°C (219°F)	110°C (230°F)	N/A	N/A
Fan Off	99°C (210°F)	105°C (221°F)	N/A	N/A
A/C On	Low	High	Low	High
Fan On	99°C (210°F)	110°C (230°F)	1, 448 kPa (210 psi)	1, 718 kPa (249 psi)
Fan Off	93°C (199°F)	105°C (221°F)	1, 207 kPa (175 Psi)	1, 585 kPa (229 Psi)

RADIATOR FAN OPERATION

EATX Fluid Temperature			Low Speed	High Speed
Fan On			109°C (228°F)	111°C (232°F)
Fan Off			104°C (220°F)	109°C (228°F)

EATX Fluid Temperature			Low Speed	High Speed
Fan On			109°C (228°F)	111°C (232°F)
Fan Off			104°C (220°F)	109°C (228°F)

The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant.

CAUTION

The power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds and become damaged.

1 - BLOCK HEATER
2 - POWER CORD

Thoroughly clean core hole and heater seat.
Insert heater assembly with element loop positioned upward .
With heater seated, tighten center screw securely to assure a positive seal. CAUTION: To prevent damage, the power cord must be secured in it's retaining clips, and not positioned so it could contact linkages or exhaust manifold.
Connect power cord to heater.
Lower vehicle.
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Clean block core hole and heater seat.
Insert heater block (1) assembly.
With block heater seated, tighten screw (2) to 12N.M (106 in.lbs.) to assure a positive seal.
Install power cord plug to block heater (1).
Fill cooling system with coolant to the proper level. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Install the A/C compressor. Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-485480-S12532763762012071300000) .

Scheme 45

Scheme 45: DESCRIPTION

1 - ACCESSORY DRIVE BELT
2 - WATER PUMP PULLEY
3 - WATER PUMP

A centrifugal water pump (2) circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine main drive belt.

The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary.

WARNING

Do not remove the cooling system pressure cap or any hose with the system hot and under pressure because serious burns from coolant can occur.

2.4L: Remove pressure cap when engine is cold. Remove small amount of coolant. Idle engine until thermostat opens. You should observe coolant flow while looking down the filler neck. Once flow is detected install the pressure cap. Replace removed coolant into coolant recovery container.
3.6L: Start engine, coolant flow should be observable in coolant pressure container when revving the engine.

If engine is cold, idle engine until normal operating temperature is reached. Feel the upper radiator hose. If it is hot, coolant is circulating.

STANDARD PROCEDURE - COOLANT AIR EVACUATION

Note. To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system.

WARNING

WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE.

Note. The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system.

Note. For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor).

Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps.
Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank.
Attach the adapter cone (2) to the vacuum gauge (1).
Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1).
Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly.
Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum.
Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse.
Close the vacuum generator/venturi ball valve.
Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly.
Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated.
Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system.
Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2).
Open the suction hose's ball valve to begin refilling the cooling system.
When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached.
Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly.
Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank.
With heater control unit in the HEAT position, operate engine with container cap in place.
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 pressure container.
Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period.
Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap.

Scheme 46

Scheme 46: 2.4L

1 - WATER PUMP PULLEY
2 - BOLT
3 - WATER PUMP
4 - WATER PUMP HOUSING
5 - NUT
6 - WATER PUMP RETURN TUBE

Remove the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
Drain engine coolant. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Raise vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-485472-S37758686622012071300000) .
Remove accessory drive belt splash shield.
Remove screws attaching water pump pulley (1). Remove pulley (1).
Remove water pump mounting bolts (2).
Remove water pump (3).

The water pump on 3.6L engines is bolted directly to the engine timing chain case cover.

Scheme 47

Scheme 47: 3.6L

Scheme 48

Scheme 49

Disconnect negative battery cable from battery. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter.
Remove the coolant bottle assembly (1) and position aside.
Using a suitable jack, support the engine.
Remove the right side engine mount assembly (4).
Remove the engine mounting block from the water pump.
Raise vehicle. CAUTION: Do not pry on the water pump at the timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
Remove the lower engine cover.
Drain coolant into clean container for reuse. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Remove right front wheel.
Remove the inner splash shield.
Remove the accessory drive belt (7). Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
Remove accessory drive belt idler pulley (2).
Disconnect the A/C compressor electrical connector.
Remove the A/C compressor (2) and position aside.
Remove the lower bypass hose and the lower radiator hose from the water pump (1) and position aside.
Remove the remainder ten water pump mounting bolts. Take notice to the four water pump bolts (2) that mount directly to the timing chain cover.
Remove water pump (1) and discard seal.

Scheme 50

Scheme 50: DISASSEMBLY

Remove the water pump assembly from the vehicle. Refer to «PUMP, WATER, REMOVAL»(ref-485484-S32813817012012071300000) .
Discard the water pump outlet gasket (7).
Remove the three bolts (1) attaching the water pump pulley (2) to the water pump (4).
Remove the water pump pulley (2).
Remove the five bolts (3) attaching the water pump (4) to the water pump adapter (6).
Remove and discard the gasket (8).
Remove the water pump (4) and inspect carefully for any damage. Refer to «PUMP, WATER, INSPECTION»(ref-485484-S03153413872012071300000) .

The water pump on 3.6L engines is bolted directly to the engine timing chain case cover.

Scheme 51

Scheme 51: 3.6L

Clean mating surfaces.
Using a new seal, position water pump and install mounting bolts. Note the shorter bolts bolt directly to the timing cover. Loosely tighten the M6 water pump mounting bolts.
Spin water pump to be sure that pump impeller does not rub against timing chain case/cover (1).
Install the idler pulley bolt (10). Tighten the mounting bolt to 25 N.m (18 ft. lbs.).
Tighten the M6 water pump mounting bolts to 12 N.m (106 in. lbs.) in sequential order. CAUTION: When installing the serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction.
Install accessory drive belt (7). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
Install the lower radiator hose and the bypass hose.
Install the right inner splash shield.
Install the right front wheel.
Lower vehicle.
Position jack under engine.
Install the engine mounting block onto the front of the water pump. Tighten the M8 mounting bolt to 25 N.m (18 ft. lbs.). Tighten the M10 mounting bolt to 55 N.m (41 ft. lbs.).
Install the engine mount. Tighten the mounting bolt to the engine block to 61 N.m (45 ft. lbs.).
Install the coolant bottle.
Install the air intake assembly.
Evacuate air and refill cooling system. Refer to «PUMP, WATER, STANDARD PROCEDURE»(ref-485484-S08201670512012071300000) .
Connect negative battery cable.
Check the cooling system for leaks. Refer to «DIAGNOSIS AND TESTING»(ref-485484-S36514498252012071300000) .

Scheme 52

Scheme 52: DESCRIPTION

1 - RADIATOR

All vehicles are equipped with a cross flow type radiator (1) with plastic side tanks.

Plastic tanks, while stronger than brass, are subject to damage by impact, such as from tools or wrenches. Handle radiator with care.

Scheme 53

Scheme 53: REMOVAL

Scheme 54

Disconnect negative cable from auxiliary jumper terminal.
Remove engine cover.
Remove air box assembly. Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485475-S36552825552012071300000) or «BODY, AIR CLEANER, REMOVAL»(ref-485476-S11662508332012071300000) .
Recover A/C system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) . WARNING: Do not remove pressure cap or any hose with the system hot and under pressure because serious burns from coolant can occur.
Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Remove the front bumper facia. Refer to «FASCIA, FRONT, REMOVAL»(ref-485477-S18042851762012071300000) .
Remove under belly pan.
Remove front bottom splash shield. 1 - ELECTRICAL CONNECTOR 2 - UPPER RADIATOR HOSE
Remove upper (2) and lower radiator hoses at radiator.
Disconnect radiator fan electrical connector (1). 1 - A/C LINE 2 - SUPPORT BRACKET
Remove the cooling fan assembly. Refer to «FAN, COOLING, REMOVAL»(ref-485484-S10344163702012071300000) .
Disconnect both A/C lines at condenser/cooler.
Remove transmission oil cooler tubes support bracket bolt at left side of radiator (2). CAUTION: Plastic tanks, while stronger than brass are subject to damage by impact, such as wrenches.
Remove the two torx screws located on the upper radiator support that hold the upper radiator mounting brackets.
Tilt the top of the radiator rearward so the mounting brackets slide out of the upper core support.
Remove radiator/condenser assembly by lifting the assembly out of the vehicle between the engine and the core support.
Separate the A/C condenser from the radiator.

Apply MOPAR™ thread sealant with PFTE part number 04318034 to sensor threads.
Install sensor (1) to cylinder head.
Tighten sensor to 11 N.m (8 ft. lbs.) torque.
Connect electrical connector to sensor.
Replace any lost engine coolant. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 55

Scheme 55: 2.4L

1 - AIR BLEED
2 - SEAL
3 - RETURN SPRING
4 - PELLET CHAMBER

The primary thermostat is located on the front of the water plenum in the thermostat housing/coolant inlet. The thermostat has an air bleed vent located on its flange. The air bleed vent (1) and the locator dimple on thermostat seal provide for proper positioning of thermostat in inlet housing.

The secondary thermostat is located in the cylinder head under the water plenum.

Scheme 56

Scheme 56: 3.6L

CAUTION

Do not operate an engine without a thermostat, except for servicing or testing.

A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up 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 warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation.

The thermostat is part of the housing.

WARNING

Do not loosen radiator draincock with system hot and pressurized. Serious burns from coolant can occur.

CAUTION

The Thermostat and housing is serviced as an assembly. Do not remove the thermostat from the housing, damage to the thermostat may occur.

Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.

If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.

Disconnect negative battery cable at battery.
Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Remove the coolant recovery bottle and position aside.
Remove upper radiator hose clamp and upper radiator hose at thermostat housing (1).
Remove thermostat housing mounting bolts.
Remove the thermostat housing (1) from the vehicle and discard the gasket seal.

Scheme 57

Remove the thermostat housing assembly. Refer to «THERMOSTAT, REMOVAL»(ref-485484-S06347051122012071300000) .
Remove the Heater supply hose from the coolant crossover (1).
Remove the coolant crossover mounting bolts. Take notice to the four bolts (2) that bolt directly to the timing cover.
Remove the coolant crossover and discard Gaskets.

Scheme 58

Scheme 58: 2.4L - PRIMARY THERMOSTAT

1 - COOLANT HOSE
2 - INLET HOUSING
3 - BOLT

Position thermostat into the water plenum, aligning air bleed with the location notch on inlet housing (2).
Install inlet housing (2) onto coolant adapter. Tighten bolts to 9 N.m (79 in. lbs.).
Connect coolant hose (1).
Install air filter housing.
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 59

Scheme 59: 2.4L - SECONDARY THERMOSTAT

1 - COOLANT HOSE (REAR)
2 - COOLANT ADAPTER
3 - RADIATOR HOSE
4 - RADIATOR HOSE (FRONT)

Position thermostat into the cylinder head.
Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter. Replace O-ring as necessary.
Lubricate O-rings with soapy water.
Position coolant adapter on water pump inlet tube and cylinder head.
Install coolant adapter mounting bolts. Tighten bolts to 18.1 N.m (159 in. lbs.).
Connect front coolant hose (1).
Connect two rear coolant hoses (1).
Connect radiator hose (3).
Install air filter housing.
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

CAUTION

The Thermostat and housing is serviced as an assembly. Do not remove the thermostat from the housing, damage to the thermostat may occur.

Clean mating areas of timing chain cover and thermostat housing (1).
Install a new gasket seal on to the thermostat housing.
Position thermostat housing on the water crossover.
Install two thermostat housing bolts. Tighten bolts to 12 N.m (106 in. lbs.).
Install upper radiator hose on thermostat housing (1).
Install the coolant recovery bottle. Tighten bolts to 8 N.m (70 in. lbs.).
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Connect negative battery cable to battery.
Start and warm the engine. Check for leaks.

3.6L COOLANT CROSSOVER

Clean gasket sealing surfaces.
Install new gasket onto the coolant crossover. NOTE: The shorter M6 mounting bolts (2), bolt directly to the engine timing cover.
Hand tighten the M6 mounting bolts. Tighten the bolts in a criss cross pattern to 12 N.m (106 in. lbs.).
Install the heater supply hose to the coolant crossover (1).
Install the thermostat housing. Refer to «THERMOSTAT, INSTALLATION»(ref-485484-S01266468242012071300000) .

Scheme 60

Scheme 60: REMOVAL

1 - NUTS
2 - WATER PUMP INLET TUBE
3 - WATER PUMP HOUSING

The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing.

Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
Remove the coolant adapter and secondary thermostat. Refer to «THERMOSTAT, REMOVAL»(ref-485484-S06347051122012071300000) .
Raise and support vehicle.
Remove inlet tube mounting nuts (1).
Remove inlet tube (2).

Scheme 61

Scheme 61: INSTALLATION

1 - NUTS
2 - WATER PUMP INLET TUBE
3 - WATER PUMP HOUSING

Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary.
Lubricate O-rings with soapy water.
Install new water inlet gasket between tube and water pump housing (2).
Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment.
Install secondary thermostat and coolant adapter. Refer to «THERMOSTAT, INSTALLATION»(ref-485484-S01266468242012071300000) .
Tighten coolant tube nuts (1) to 24 N.m (212 in. lbs.).
Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 62

Scheme 62: DISCONNECT

1 - QUICK CONNECT FITTING
2 - DUST CAP
3 - OIL COOLER LINE
4 - SPECIAL TOOL 8875A

Remove dust cap by pulling it straight back off of quick connect fitting (1).
Place properly sized Release Tool (4) onto transmission cooler line with the fingers of the tool facing the quick connect fitting.
Slide Release Tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting.
Rotate the release tool 60° to expand the retaining clip.
While holding the release tool against the quick connect fitting, pull back on the transmission cooler line to remove.
If quick connect fitting is damaged or leaking at transmission oil cooler or transmission, remove fitting.

Scheme 63

Scheme 63: CONNECT

1 - QUICK CONNECT FITTING
2 - CLIP
3 - OIL COOLER LINE
4 - DUST CAP

If removed, install quick connect fitting into transmission oil cooler or transmission. Tighten fitting to 15 N.m (132 in. lbs.).
Align transmission cooler line (3) with quick connect fitting while pushing straight into the fitting.
Push in on transmission cooler line until a "click" is heard or felt.
Slide dust cap (4) down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed.

Note. If dust cap will not snap into place, repeat assembly step #2.

Engine Cooling System: Other Dodge Avenger II рестайлинг

COOLING SYSTEM FLOW - 2.4L

Scheme 29

TRAILER TOWING

RECENT SERVICE OR ACCIDENT REPAIR

FLOW CHECK

PREFERRED METHOD

ALTERNATIVE METHOD

Scheme 30

PRESSURE TESTER METHOD

AERATION

2.4L

3.6L/2.0L DIESEL

Scheme 31

Scheme 32

ADDING ADDITIONAL COOLANT

CLEANING

CHEMICAL CLEANING

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

3.6L

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

NON-PRESSURE SYSTEM

PRESSURE SYSTEM

Scheme 43

Scheme 44

GAS ENGINES AND DIESEL ENGINES

RADIATOR FAN CONTROL

Scheme 45

STANDARD PROCEDURE - COOLANT AIR EVACUATION

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

3.6L COOLANT CROSSOVER

Scheme 60

Scheme 61

Scheme 62

Scheme 63

More articles — Engine Cooling System

Login / Signup

Enter the code

You have successfully logged in!