Engine Cooling System: Removal & Installation Dodge Cab & Chassis R3500 HD

INSTALLATION-3.7L/4.7L

Scheme 37

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. NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.
2. Position accessory drive belt around all pulleys except the idler pulley.
3. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler and slowly release tensioner rotate into accessory drive belt. Make sure the belt is seated onto all pulleys. 1 - AUTOMATIC TENSIONER ASSEMBLY
4. 4.7L Engines Only - With the drive belt installed, inspect the belt wear indicator. Gap between the tang and the housing stop (measurement A) must not exceed 24 mm (.94 inches). If the measurement exceeds this specification replace the accessory drive belt.

INSTALLATION-5.7L

Note. When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.

1. Position the drive belt over all pulleys except for the water pump pulley.
2. Rotate tensioner clockwise and slip the belt over the water pump pulley.
3. Gently release tensioner.
4. Install the air intake tube between intake manifold and air filter assembly.

INSTALLATION-5.9L/6.7L DIESEL

1. Position drive belt over all pulleys except water pump pulley.
2. Attach a suitable tool to the accessory drive belt tensioner. 1 - IDLER PULLEY 2 - ACCESSORY DRIVE BELT 3 - P/S PULLEY 4 - RADIATOR FAN PULLEY 5 - CRANKSHAFT PULLEY 6 - ACCESSORY DRIVE BELT TENSIONER 7 - GENERATOR 8 - WATER PUMP
3. Rotate accessory drive belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove tool. Be sure belt is properly seated on all pulleys.

ACCESSORY DRIVE BELT TENSIONER-INSTALLATION-5.7L

Note. When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.

1. Install tensioner (1) on to the mounting bracket. Tighten bolt (2) to 41 N.m (30 ft. lbs.).
2. Install tensioner and bracket assembly
3. Install accessory drive belt. See «INSTALLATION»(ref-303804-S26300019162008103100000) .

Note. When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.

1. Install pulley and pulley bolt to tensioner (3). Tighten bolt to 61 N.m (45 ft. lbs.) torque.
2. An indexing slot is located on back of tensioner (3). Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt (2) to 41 N.m (30 ft. lbs.).
3. Install accessory drive belt. See «INSTALLATION»(ref-303804-S26300019162008103100000) .
4. Check tensioner indexing marks.

1. Install tensioner assembly (7) to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 N.m (32 ft. lbs.) torque.
2. Install drive belt. See «INSTALLATION»(ref-303804-S26300019162008103100000) .

COOLANT RECOVERY CONTAINER-INSTALLATION-3.7L/4.7L/5.7L ENGINE

1. Align the coolant container mounting pins into the slots on the fan shroud (5) and push the container onto the fan shroud.
2. Secure the container to the fan shroud with the bolts (1). Tighten to 8.5 N.m (75 in. lbs). NOTE: Ensure that the locking feature on the mounting pins has engaged.
3. Connect the recovery hose (3) to the radiator (4).
4. Connect washer pump electrical connector.

1. Position coolant recovery bottle (2) on bracket (3).
2. Install mounting bolts (4). Tighten to 8.5 N.m (75 in. lbs).
3. Install overflow hose (5) onto radiator (1).

Scheme 38

An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L/4.7L gas powered engines have the block heater located to the rear on the right side of the engine.

Scheme 39

The diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (1).

Scheme 40

The 5.7L engine has the block heater (1) located on the left side of the engine below the exhaust manifold in the rear of the engine and is not immersed in engine coolant but makes direct contact with the block.

ENGINE BLOCK HEATER-REMOVAL-5.7L

1. Raise vehicle.
2. Remove power cord from block heater (1).
3. Remove bolt (2) on block heater (1). Remove heater assembly (1).

REMOVAL-5.9L/6.7L DIESEL

1. Disconnect the battery negative cables.
2. Drain coolant from radiator and cylinder block. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000).
3. Unscrew the power cord retaining cap and disconnect cord from heater element.
4. Using a suitable size socket, loosen and remove the block heater element. see scheme 42

ENGINE BLOCK HEATER-INSTALLATION- 3.7L/4.7L

1. Clean and inspect the block heater hole.
2. Install the new O-ring seal(s) to heater.
3. Insert the block heater (1) into cylinder block and position the element properly.
4. With the heater fully seated, tighten center screw to 2 N.m (17 in. lbs.).
5. Fill the cooling system with the recommended coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
6. Start and warm the engine.
7. Check the block heater for leaks.

ENGINE BLOCK HEATER-INSTALLATION-5.7L

1. Thoroughly clean cylinder block core hole and block heater seat.
2. Insert block heater assembly (1) into the block.
3. With block heater fully seated, tighten bolt (1) to 2 N.m (17 in. lbs.) torque.

1. Clean and inspect the threads in the cylinder block and heater element.
2. Coat heater element threads with Mopar® Thread Sealer with Teflon.
3. Screw block heater (1) into cylinder block and tighten to 75 N.m (55 ft. lbs.).
4. Connect block heater cord and tighten retaining cap.
5. Fill cooling system with recommended coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
6. Start and warm the engine.
7. Check block heater for leaks.

ENGINE COOLANT TEMPERATURE SENSOR-INSTALLATION - 4.7L

1. Apply thread sealant to ETC sensor threads.
2. Install ETC sensor (1) to engine.
3. Tighten ETC sensor to 11 N.m (8 ft. lbs.) torque.
4. Connect electrical connector to ETC sensor (1).
5. Replace any lost engine coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .

ENGINE COOLANT TEMPERATURE SENSOR-INSTALLATION-3.7L

1. Apply thread sealant to ETC sensor threads.
2. Install ETC sensor (3) to engine.
3. Tighten sensor to 11 N.m (8 ft. lbs.) torque.
4. Connect electrical connector to ETC sensor (3).
5. Replace any lost engine coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .

ENGINE COOLANT TEMPERATURE SENSOR-INSTALLATION-5.7L

1. Apply thread sealant to ETC sensor threads.
2. Install ETC sensor (3) into engine.
3. Tighten sensor to 11 N.m (8 ft. lbs.) torque.
4. Connect electrical connector to ETC sensor (3).
5. Install air conditioning compressor onto the front of engine. Refer to «INSTALLATION»(ref-303776-S29433656782008103100000) .
6. Install accessory drive belt. See «INSTALLATION»(ref-303804-S26300019162008103100000) .
7. Replace any lost engine coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .

1. Install sensor (1 or 3) to engine.
2. Tighten sensor to 18 N.m (13 ft. lbs.) torque. 1 - THERMOSTAT HOUSING 2 - ELECTRICAL CONNECTOR 3 - ECT SENSOR
3. Connect electrical connector (2) to ETC sensor (1 or 3).
4. Install heat shield (if equipped).
5. Replace any lost engine coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .

Scheme 41

The electronically controlled viscous fan drive is attached to the fan drive pulley mounted to the engine. The coupling allows the fan to be driven in a normal manner.

The Engine Control Module (ECM) controls the level of engagement of the electronically controlled viscous fan clutch by monitoring coolant temperature, intake manifold temperature, air conditioning pressure and transmission oil temperature. Based on cooling requirements, the ECM sends a signal to the viscous fan clutch to increase or decrease the fan speed.

Fan speed is monitored by the ECM. Fan speeds above or below a calibrated threshold will set a DTC. Circuit concerns will also set fan clutch DTC's.

Scheme 42

A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown in illustration. 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.

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.

INSTALLATION-3.7L/4.7L/5.7L

Note. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 RPM and hold for approximately two minutes. This will ensure proper fluid distribution within the drive.

1. Install fan blade assembly to the viscous fan drive. Tighten the bolts to 24 N.m (18 ft. lbs.) torque. see scheme 60
2. Position the fan shroud and the fan blade/viscous fan drive assembly to the vehicle as a complete unit.
3. Install the fan shroud.
4. Install the fan blade/viscous fan drive assembly to the water pump shaft. see scheme 60 Tighten mounting nut to 50 N.m (37 ft. lbs.).
5. Install the coolant reserve/overflow container to the fan shroud.
6. Connect the negative battery cable.

Note. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 RPM and hold for approximately two minutes. This will ensure proper fluid distribution within the drive.

1. Install fan blade assembly to electrically controlled viscous fan drive. Tighten mounting bolts to 24 N.m (18 ft. lbs.) torque.
2. Loosen both upper engine mounted fan shroud brackets.
3. Make sure lower engine mounted fan shroud bracket bolts are tightened to 24 N.m (18 ft. lbs.).
4. Position fan/fan drive assembly inside fan shroud and lower into position.
5. Install the viscous fan drive assembly onto fan pulley hub shaft. Tighten mounting nut to 115 N.m (85 ft. lbs.) torque.
6. Install fan drive wire harness support to fan shroud.
7. Install viscous fan wiring bracket onto lower fan shroud bracket. Tighten nut to 14 N.m (11 ft. lbs.).
8. Install fan shroud onto fan shroud brackets.
9. Connect fan drive wire harness. 1 - NUTS 2 - ENGINE MOUNTED FAN SHROUD
10. Install fan shroud to upper engine fan shroud brackets. Tighten nut finger tight.
11. Tighten upper engine fan shroud bracket bolts to 24 N.m (18 ft. lbs.).
12. Tighten four fan shroud bracket nuts to 24 N.m (18 ft. lbs.).
13. Make sure of fan tip clearance all the way around inside of fan shroud.
14. Connect the battery negative cables.

Scheme 43

The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. see scheme 70

This radiator does not contain an internal transmission oil cooler.

INSTALLATION-3.7L/4.7L/5.7L ENGINE

Note. The radiator is equipped with one alignment dowel on the bottom of the outlet tank and one retaining bracket on the front side of the inlet tank. Both features have rubber insulators attached to them that must be present. The alignment dowel fits into a hole at the bottom of the front end sheet metal vertical support post and the support bracket rests on top of the lower radiator closure tube.

1. Position the fan shroud over the fan blades rearward towards engine.
2. Install the rubber insulators to the lower radiator mounting features (alignment dowel and support bracket at the lower part of the radiator).
3. Lower the radiator into position while guiding the alignment dowel into the vertical post bracket. Position and seat the lower radiator support bracket onto the lower radiator closure tube.
4. Install the upper radiator mounting bolts. Tighten bolts to 10 N.m (90 in. lbs.).
5. Connect the lower radiator hose and install the clamp in the proper position.
6. Connect the power steering hoses to the power steering oil cooler and install the clamps.
7. Connect the transmission oil cooler lines to the transmission oil cooler and install the secondary latches. 1 - RADIATOR 2 - SCREWS 3 - FAN SHROUD 4 - SLIDE MOUNT
8. Position the fan shroud into the mounting clips on the radiator tanks and secure with bolts. Tighten the bolts to 8 N.m (75 in. lbs.).
9. Secure the power steering hoses into the clip on the lower fan shroud.
10. Install the windshield washer reservoir tank and connect the hose and electrical connector.
11. Install coolant reserve/overflow container hose(s) to radiator filler neck and secure properly with clamps.
12. Install coolant reserve/overflow container or degas container to fan shroud and tighten the bolts to 8 N.m (75 in. lbs.).
13. Connect upper radiator hose and install clamp.
14. Install battery negative cable.
15. Fill cooling system with coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
16. Operate the engine until it reaches normal operating temperature. Check cooling system fluid levels.

INSTALLATION-5.9L/6.7L DIESEL ENGINE

1. Install rubber insulators to alignment dowels at lower part of radiator.
2. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application.
3. Install two upper radiator mounting bolts. Tighten bolts to 12 N.m (105 in. lbs.) torque.
4. Connect both radiator hoses and install hose clamps.
5. If equipped, connect transmission cooler lines to transmission cooler. Inspect quick connect fittings for debris and install until an audible "click" is heard. Tug on lines to verify connection. See «STANDARD PROCEDURE»(ref-303804-S37961335992008103100000) .
6. Position power steering cooler on the radiator and tighten nuts to 10 N.m (90 in. lbs.)
7. Position fan shroud on brackets.
8. Install fan shroud mounting nut. Tighten nut to 24 N.m (18 ft. lbs.).
9. Install the coolant recovery container. See «INSTALLATION»(ref-303804-S24038862872008103100000) .
10. Position coolant recovery tank hose, washer bottle hose, and the positive battery cable into the clips located on the top of the radiator. See «INSTALLATION»(ref-303804-S24038862872008103100000) .
11. Install air box and turbocharger inlet hose. Refer to «INSTALLATION»(ref-303792-S42803344782008103100000) for 5.9L, or «INSTALLATION»(ref-303793-S39793439192008103100000) for 6.7L. Tighten clamps to 4 N.m (35 in. lbs.).
12. Connect mass airflow sensor electrical connector and ambient air temp sensor electrical connector (if equipped).
13. Position heater controls to full heat position.
14. Fill cooling system with coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
15. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels.

Scheme 44

Scheme 45

The thermostat of the diesel engine is located in the front of the cylinder head, underneath a heat shield near the thermostat housing. (Scheme 44)

Note. The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled.

An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat will cause overheating.

Scheme 46

The 3.7L/4.7L/5.7L engines use a pellet-type thermostat that controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. The 8.3L engine uses a movable sleeve type thermostat. 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.

Coolant leakage into the pellet container will cause the thermostat to fail in the open position. Thermostats very rarely stick. Do not attempt to free a thermostat with a prying device.

Scheme 47

On the 3.7L/4.7L engine the thermostat is designed to block the flow of the coolant bypass journal by 50% instead of completely blocking the flow. This design controls coolant temperature more accurately. (Scheme 47)

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.

REMOVAL-5.9L DIESEL

1. Disconnect the battery negative cables.
2. Drain cooling system until coolant level is below thermostat. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
3. Remove radiator hose clamp and hose from thermostat housing (1).
4. Remove the three water thermostat housing bolts and remove thermostat housing (1).
5. Clean the mating surfaces of thermostat housing (1) and clean the thermostat seat groove at the top of the thermostat housing (1).

REMOVAL-6.7L DIESEL

1. Disconnect the battery negative cables.
2. Remove vent plug near EGR cooler.
3. Drain cooling system until coolant level is below thermostat. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
4. Disconnect exhaust gas pressure sensor electrical connector (3).
5. Remove exhaust pressure tube (4) from thermostat housing.
6. Remove EGR cooler cross over tube (1).
7. Remove radiator hose clamp and hose from thermostat housing (1).
8. Remove heat shield.
9. Remove the three water outlet-to-cylinder head bolts (5) and remove the water outlet connector.
10. Clean the mating surfaces of the thermostat housing (1) and clean the thermostat seat groove at the top of the thermostat housing (1).

1. Clean the mating areas of the timing chain cover and the thermostat housing.
2. Install the thermostat (spring side down) into the recessed machined groove on the timing chain cover. CAUTION: The housing must be tightened evenly and the thermostat must be centered into the recessed groove in the timing chain cover. If not, it may result in a cracked housing, damaged timing chain cover threads or coolant leaks.
3. Position the thermostat housing on the timing chain cover.
4. Install the housing-to-timing chain cover bolts. Tighten the bolts to 13 N.m (112 in. lbs.).
5. Install the lower radiator hose on the thermostat housing.
6. Install the splash shield.
7. Lower the vehicle.
8. Fill the cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
9. Connect negative battery cable.
10. Start and warm the engine. Check for leaks.

1. Position the thermostat and housing (2) on the front cover.
2. Install thermostat housing bolts (1). Tighten the bolts (1) to 13 N.m (112 in. lbs.).
3. Install the radiator hose (4) onto the thermostat housing (2).
4. Fill the cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
5. Connect negative battery cable.
6. Start and warm the engine. Check for leaks.

INSTALLATION-5.9L DIESEL

Note. The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled.

1. Inspect thermostat seal for cuts or nicks. Replace if damaged.
2. Install the thermostat into the groove in the top of the cylinder head (2).
3. Install the thermostat housing (1) and bolts. Tighten the bolts to 10 N.m (89 in. lbs.) torque.
4. Install the radiator upper hose and clamp.
5. Fill the cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
6. Connect the battery negative cables.
7. Start the engine and check for coolant leaks. Run engine to check for proper thermostat operation.

INSTALLATION-6.7L DIESEL

Note. The thermostat for 5.9L engine and the 6.7L are different and are not interchangeable. Use caution when replacing the thermostat to ensure the proper part number is reinstalled.

1. Inspect thermostat seal for cuts or nicks. Replace if damaged.
2. Install the thermostat into the groove in the top of the cylinder head.
3. Install the thermostat housing and bolts (5). Tighten the bolts to 10 N.m (89 in. lbs.).
4. Install heat shield. Tighten bolts to 9 N.m (79 in. lbs.).
5. Install exhaust pressure tube (4). Tighten to 10 N.m (88 in. lbs.).
6. Connect exhaust pressure sensor electrical connector (2).
7. Install EGR cross over tube (1).
8. Install P-clip and bolt. Tighten to 8 N.m (70 in. lbs.).
9. Install the radiator upper hose and clamp.
10. Fill the cooling system with coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
11. Connect the battery negative cables.
12. Start the engine and check for coolant leaks. Run engine to check for proper thermostat operation.

Scheme 48

All cooling systems are equipped with a pressure cap. (Scheme 48) For all engines, the pressure cap is located on top of the radiator outlet tank. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap

The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi).

A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure.

REMOVAL-3.7L/4.7L

The water pump on 3.7L/4.7L engines is bolted directly to the engine timing chain case cover.

Scheme 49

1. Disconnect the negative battery cable.
2. Drain cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000).
3. Remove fan/viscous fan drive assembly from water pump. See «REMOVAL»(ref-303804-S08952103862008103100000). Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
4. If the water pump is being replaced, do not unbolt the fan blade assembly from the thermal viscous fan drive. 1 - AUTOMATIC TENSIONER 2 - WATER PUMP PULLEY
5. Remove the radiator fan. See «REMOVAL»(ref-303804-S08952103862008103100000).
6. Remove accessory drive belt. (Scheme 49)and «REMOVAL»(ref-303804-S28153607332008103100000).
7. Remove the lower radiator hose clamp and remove the lower hose at the water pump.
8. Remove the water pump mounting bolts. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
9. Remove the water pump and gasket. Discard gasket.

Scheme 50

1. Disconnect negative battery cable.
2. Drain coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
3. Remove accessory drive belt. See «REMOVAL»(ref-303804-S28153607332008103100000) .
4. Remove radiator fan. See «REMOVAL»(ref-303804-S08952103862008103100000) .
5. Remove coolant recovery container. See «REMOVAL»(ref-303804-S19772450802008103100000) .
6. Disconnect washer bottle wiring and hose.
7. Remove fan shroud assembly.
8. Remove A/C compressor and generator brace. Refer to «REMOVAL»(ref-303776-S12199686782008103100000) .
9. Remove accessory drive belt tensioner. See «REMOVAL»(ref-303804-S37527405682008103100000) .
10. Remove upper and lower radiator hoses.
11. Remove heater hoses.
12. Remove water pump mounting bolts and remove pump.

Scheme 51

1. Disconnect battery negative cables.
2. Drain cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped).
4. Remove turbocharger inlet tube and air filter housing. Refer to «REMOVAL»(ref-303792-S18526032722008103100000) for 5.9L or «REMOVAL»(ref-303793-S10243900702008103100000) for 6.7L.
5. Remove generator assembly. Refer to «REMOVAL»(ref-303807-S07897203792008103100000) .
6. Remove the accessory drive belt. See «REMOVAL»(ref-303804-S28153607332008103100000) .
7. Remove water pump mounting bolts (3).
8. Remove O-ring from water pump.
9. Clean water pump sealing surface on cylinder block.

1. Install water pump and mounting bolts. Tighten mounting bolts to 24 N.m (18 ft. lbs.).
2. Install heater hoses.
3. Install upper and lower radiator hoses.
4. Install accessory drive belt tensioner. See «INSTALLATION»(ref-303804-S02120090792008103100000) .
5. Install A/C compressor and alternator brace. Refer to «INSTALLATION»(ref-303776-S29433656782008103100000) . Tighten bolt and nuts to 28 N.m (21 ft. lbs.).
6. Install radiator fan. See «INSTALLATION»(ref-303804-S15062987112008103100000) .
7. Install accessory drive belt. See «INSTALLATION»(ref-303804-S26300019162008103100000) .
8. Connect washer bottle wiring and hose.
9. Install coolant recover container. See «INSTALLATION»(ref-303804-S24038862872008103100000) .
10. Connect negative battery cable.
11. Fill coolant. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
12. Start and warm the engine. Check for leaks.

Scheme 52

1. Install new O-ring seal in groove on water pump. (Scheme 52) 1 - BOLT 2 - WATER PUMP
2. Install water pump with the weep hole facing downward. Tighten mounting bolts to 24 N.m (18 ft. lbs.) torque.
3. Install generator assembly. Refer to «INSTALLATION»(ref-303807-S29513139892008103100000).
4. Install accessory drive belt. See «INSTALLATION»(ref-303804-S26300019162008103100000).
5. Install air box and tube assembly. Refer to «INSTALLATION»(ref-303792-S42803344782008103100000) for 5.9L or «INSTALLATION»(ref-303793-S39793439192008103100000) for 6.7L.
6. Install air filter housing. Refer to «INSTALLATION»(ref-303792-S42803344782008103100000) for 5.9L or «INSTALLATION»(ref-303793-S39793439192008103100000) for 6.7L.
7. Fill cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000).
8. Connect both battery cables.
9. Start and warm the engine. Check for leaks.

REMOVAL-P/U

Scheme 53

1. Remove engine cover (1).
2. Drain cooling system below level of EGR cooler. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) . 1 - ELECTRICAL CONNECTOR 2 - MOUNTING BOLTS
3. Disconnect EGR bypass control electrical connector (1).
4. Remove EGR bypass control assembly mounting bolts (2) and position aside.
5. Remove air transfer tube assembly heat shield. 1 - EGR COOLER TO CROSSOVER TUBE CLAMP 2 - EGR CROSSOVER TUBE 3 - EGR VALVE TO CROSSOVER TUBE CLAMP 4 - EGR VALVE TEMPERATURE SENSOR CONNECTOR 5 - CLAMP
6. Loosen EGR valve mounting bolts. Do not remove bolts.
7. Remove EGR crossover tube to EGR cooler and EGR valve clamps (1 and 3).
8. Remove EGR crossover tube clamp (5).
9. Remove EGR crossover tube (2).
10. Remove clamp at front of EGR cooler.
11. Remove Air Transfer Tube assembly.
12. If damaged, separate Air Transfer Tube from Brace assembly. Discard gasket. 1 - NUTS 2 - EGR COOLER 3 - LOCKING CONSTANT TENSION CLAMPS 4 - EGR CROSSOVER TUBE CLAMP 5 - EGR CROSSOVER TUBE 6 - FRONT COOLANT TUBE 7 - BREATHER TUBE 8 - REAR COOLANT TUBE
13. Using Tool 6094, remove forward coolant tube (6) from EGR cooler (2).
14. Using Tool 6094, remove breather tube (7).
15. Using Tool 6094, remove rear coolant tube (8) from EGR cooler (2).
16. Remove EGR Transfer Connection Tube from casting.
17. Remove EGR cooler flange nuts (1).
18. Remove EGR cooler mount bolts.
19. Remove EGR cooler. Discard flange gasket.
20. If damaged, remove EGR cooler mounting support.

Scheme 54

1. Remove EGR Cooler. See «REMOVAL»(ref-303804-S28100764792008103100000) .
2. Spray the internal cavity of EGR Cooler with hot tap water for 10 minutes.
3. Plug EGR Cooler outlet (1) with a locally obtained rubber expansion plug to make a watertight seal.
4. Following instruction on the container, mix MOPAR® EGR System Cleaner and hot tap water with a ratio of one part EGR Cleaner, four parts water.
5. Position EGR Cooler with the outlet (1) facing up. Fill EGR Cooler with hot tap water and MOPAR® EGR System Cleaner until cooler is completely full. Soak for one hour.
6. Remove plug from EGR Cooler outlet (1). Drain cleaning solution from cooler. Discard according to local governmental regulations.
7. Rinse cooler using hot tap water until all cleaning solution has been rinsed clean. Dry completely.
8. Install EGR Cooler. See «INSTALLATION»(ref-303804-S08318481332008103100000) .

INSTALLATION-CAB CHASSIS

Scheme 55

1. Install EGR cooler support bracket, if removed. Tighten mounting bolts to 32 N.m (24 ft. lbs.).
2. Using a new gasket, position EGR cooler (2) on exhaust manifold flange. Tighten flange nuts to 43 N.m (32 ft. lbs).
3. Install EGR Cooler mounting bolts. Using a crisscross pattern, tighten bolts to 24 N.m (18 ft. lbs.). 1 - LOCKING CONSTANT TENSION CLAMP 2 - COOLANT HOSE 3 - SCREWDRIVER 4 - COOLANT TUBE CAUTION: Locking constant tension clamps will SNAP when released. NOTE: Locking constant tension clamps can be released using a suitable screwdriver.
4. Position locking constant tension clamp (1) on froward coolant tube (4) and install tube.
5. Using a suitable screwdriver (3), release constant tension clamp (1).
6. Position locking constant tension clamp on rear coolant tube and install tube.
7. Using a suitable screwdriver, release constant tension clamp
8. Position locking constant tension clamp on breather tube and install tube.
9. Using a suitable screwdriver, release constant tension clamp. 1 - EGR COOLER TO CROSSOVER TUBE CLAMP 2 - EGR CROSSOVER TUBE 3 - EGR VALVE TO CROSSOVER TUBE CLAMP 4 - EGR VALVE TEMPERATURE SENSOR CONNECTOR 5 - CLAMP
10. Using new gasket, position EGR crossover tube (2) to EGR Cooler. Install clamp (1) finger tight.
11. Using new gasket, position EGR crossover tube (2) to EGR Valve (3). Install clamp (1) finger tight.
12. Tighten clamps (1 and 3) to 10 N.m (89 in. lbs.).
13. Install clamp (5). Tighten clamp to 10 N.m (89 in. lbs.).
14. Tighten EGR Valve mounting bolts to 24 N.m (18 ft. lbs.)
15. Install EGR Valve heat shield. Tighten mounting nut to 10 N.m (89 in. lbs.).
16. Connect EGR valve electrical connector (4). 1 - ENGINE COVER 2 - COVER MOUNTING BOLTS 3 - ROCKER COVER
17. Install engine cover (1).
18. Connect negative battery cable.
19. Fill cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .

INSTALLATION-P/U

Scheme 56

1. Install EGR cooler support bracket, if removed. Tighten mounting bolts to 32 N.m (24 ft. lbs.).
2. Using a new gasket, position EGR cooler (2) on exhaust manifold flange. Tighten flange nuts to 43 N.m (32 ft. lbs).
3. Install EGR Cooler mounting bolts. Using a crisscross pattern, tighten bolts to 24 N.m (18 ft. lbs.).
4. If separated, using a new gasket, assemble brace and Air Transfer tube. Tighten bolts to 24 N.m (18 ft. lbs).
5. Using a new gasket, install Air Transfer Tube assembly on exhaust manifold. Tighten nuts to 43 N.m (32 ft. lbs).
6. Install clamp at EGR Cooler. Tighten clamp to 10 N.m (89 in. lbs.). 1 - EGR VALVE CLAMP 2 - GASKET 3 - BOLT 4 - EGR CROSSOVER TUBE 5 - GASKET 6 - EGR COOLER CLAMP 7 - BRACE
7. Using new gasket (5), position EGR crossover tube (4) to EGR Cooler. Install clamp (6) finger tight.
8. Using new gasket (2), position EGR crossover tube (4) to EGR Valve. Install clamp (1) finger tight.
9. Tighten clamps (1 and 6) to 10 N.m (89 in. lbs.).
10. Install brace bolt (3). Tighten bolt (3) to 24 N.m (18 ft. lbs.).
11. Tighten EGR Valve mounting bolts to 24 N.m (18 ft. lbs.)
12. Install EGR Valve heat shield. Tighten mounting nut to 10 N.m (89 in. lbs.).
13. Install Air Transfer Tube heat shield. Tighten bolt to 10 N.m (89 in. lbs.). 1 - ELECTRICAL CONNECTOR 2 - MOUNTING BOLTS
14. Install EGR Control Assembly so that wire cable restraint is tight. Tighten mounting bolts to 24 N.m (18 ft. lbs.).
15. Install EGR Control Assembly electrical connector (1). 1 - LOCKING CONSTANT TENSION CLAMP 2 - COOLANT HOSE 3 - SCREWDRIVER 4 - COOLANT TUBE CAUTION: Locking constant tension clamps will SNAP when released. NOTE: Locking constant tension clamps can be released using a suitable screwdriver.
16. Position locking constant tension clamp (1) on froward coolant tube (4) and install tube.
17. Using a suitable screwdriver (3), release constant tension clamp (1).
18. Position locking constant tension clamp on rear coolant tube and install tube.
19. Using a suitable screwdriver, release constant tension clamp
20. Position locking constant tension clamp on breather tube and install tube.
21. Using a suitable screwdriver, release constant tension clamp.
22. Fill coolant system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
23. Install engine cover.
24. Connect negative battery cable(s).
25. Start engine and check for coolant or exhaust leaks.

Scheme 57

The 5.9L diesel models equipped with an automatic transmission are equipped with a water-to-oil cooler and a separate air-to-oil cooler. Both coolers are supplied as standard equipment on diesel engine powered models when equipped with an automatic transmission.

The water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine. (Scheme 57)

Scheme 58

The 6.7L model diesel with automatic transmission is equipped with an air-to-oil cooler only. This cooler is located in front of the radiator. (Scheme 58)

Scheme 59

An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler. (Scheme 59)

REMOVAL-AIR TO OIL COOLER-DIESEL

1. Remove Charge Air Cooler. Refer to «REMOVAL»(ref-303808-S33831638072008103100000).
2. Place a drain pan under the oil cooler.
3. Raise the vehicle.
4. Disconnect the oil cooler quick-connect fittings from the transmission lines. See «STANDARD PROCEDURE»(ref-303804-S37961335992008103100000).
5. Remove the charge air cooler-to-oil cooler bolt. see scheme 120
6. Remove two mounting nuts.
7. Remove the oil cooler and line assembly towards the front of vehicle. Cooler must be rotated and tilted into position while removing.

REMOVAL-WATER TO OIL COOLER-5.9L

1. Disconnect both battery negative cables.
2. Remove starter. Refer to «REMOVAL»(ref-303809-S11856902252008103100000).
3. Drain cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000).
4. Disconnect coolant lines from cooler. NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler.
5. Disconnect transmission oil lines from cooler. Plug cooler lines to prevent oil leakage.
6. Remove cooler bracket to transmission adapter bolt.
7. Remove wire harness push in clip at bottom of coolant bracket.
8. Remove wire harness push in clip at bottom of coolant bracket.
9. Remove two cooler bracket to block bolts.
10. Remove cooler assembly from vehicle. see scheme 121

Scheme 60

Note. The transmission oil cooler uses an internal thermostat to control transmission oil flow through the cooler. This thermostat is serviceable.

1. Remove the transmission oil cooler. See «REMOVAL»(ref-303804-S14007090342008103100000).
2. Remove the snap ring retaining the thermostat end plug. (Scheme 60)
3. Remove the end plug, thermostat and spring from transmission oil cooler. (Scheme 60)

INSTALLATION-3.7L ENGINE

1. Position the transmission cooler tubes to the front of the radiator by sliding brackets into slots on radiator inlet tank.
2. Snap the transmission cooler tubes into the clips on the side of the radiator tank.
3. Install the transmission cooler attaching bolt. Tighten the bolt to 16 N.m (140 in. lbs.).
4. Inspect the quick connect fittings for debris and install the quick connect fitting on the cooler tube until an audible "click" is heard. Pull apart the connection to verify proper installation and install the secondary latches. See «STANDARD PROCEDURE»(ref-303804-S37961335992008103100000) .
5. Start the engine and check all fittings for leaks.
6. Check the fluid level in the automatic transmission. Refer to «42RLE - SERVICE INFORMATION»(ref-303777) , «48RE - SERVICE INFORMATION»(ref-303779) , «545RFE - SERVICE INFORMATION»(ref-303778) , or «68RFE - SERVICE INFORMATION»(ref-303891) .

INSTALLATION-AIR TO OIL-DIESEL

1. Carefully position the oil cooler assembly to the vehicle.
2. Install two nuts and one bolt. Tighten to 11 N.m (95 in. lbs.) torque.
3. Connect the quick-connect fittings to the transmission cooler lines. See «STANDARD PROCEDURE»(ref-303804-S37961335992008103100000) .
4. Install Charge Air Cooler. Refer to «INSTALLATION»(ref-303808-S33760780322008103100000) .
5. Start the engine and check all fittings for leaks.
6. Check the fluid level in the automatic transmission.

INSTALLATION-WATER-TO-OIL-5.9L

1. Position oil cooler on cylinder block.
2. Install 2 capscrews to cylinder block finger tight.
3. Install capscrews at the transmission adapter. Torque bolt to 24 N.m (18 ft. lbs.)
4. Tighten lower mounting bolt to cooler at the cylinder block. Tighten to 77 N.m (57 ft. lbs.). NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler.
5. Tighten upper mounting bolt to cooler at cylinder block to 24 N.m (18 ft. lbs).
6. Install wire harness push in clip at bottom of cooler bracket.
7. Install starter motor. Refer to «INSTALLATION»(ref-303809-S07198546752008103100000) .
8. Connect battery negative cables.
9. Fill cooling system. See «STANDARD PROCEDURE»(ref-303804-S21721751352008103100000) .
10. Check transmission oil level and fill as necessary.

Scheme 61

1. Remove dust cap by pulling it straight back off of quick connect fitting
2. Place disconnect tool Special Tool 8875A onto transmission cooler line with the fingers of the tool facing the quick connect fitting.
3. Slide disconnect 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.
4. Rotate the disconnect tool 60° to expand the retaining clip.
5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove.

Scheme 62

1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting.
2. Push in on transmission cooler line until a "click" is heard or felt.
3. Slide dust cap 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 .