Engine Cooling System: Other Dodge Caliber I рестайлинг

GAS ENGINE

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. It also provides hot water (coolant) for heater performance and cooling for automatic transmission oil. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radiator, and then transferring this heat to the ambient air.

1. When the engine is cold and both the primary and secondary thermostats are closed. The coolant will circulate through the engine, heater system, and the bypass. The cooling system has no flow through the radiator
2. As the engine warms up, the primary thermostat will start to open at 77 °C (170 °F). Coolant will start to flow through the radiator and the internal transmission cooler. The primary thermostat will fully open at 95 °C (203 °F).
3. The secondary thermostat will start to open at 95 °C (203 °F). This will increase the coolant flow through the cylinder block and cylinder head and the radiator. The secondary thermostat will fully open at 104 °C (220 °F).

Scheme 55

The water pump draws coolant from the radiator and delivers it to the engine block. The coolant travels through the engine block into the cylinder head. Coolant exits the engine at the thermostat. If the coolant temperature is less than 87°C (189°F) the thermostat directs all of the coolant back to the water pump. If the coolant temperature is between 87°C (189°F) and 102°C (216°F) the thermostat is in the mix mode and directs the coolant to the radiator and the water pump. If the coolant is greater than 102°C (216°F), the thermostat directs all of the coolant to the radiator.

The thermostat also feeds excess coolant and bleeds air from the system through a hose leading to the coolant reservoir. The reservoir returns coolant to the inlet side of the water pump. A port and hose at the rear of the engine block provides coolant to the heater core. This coolant is returned to the engine at the intake side of the water pump.

The oil cooler receives coolant directly from the engine block. A hose returns this coolant to the inlet side of the water pump.

AERATION

If coolant level drops below a certain point, aeration will occur drawing air into the water pump resulting in the following

1. High reading shown on the temperature gauge.
2. Loss of coolant flow through the heater core.
3. Corrosion in the cooling system.
4. Transmission oil will become hotter (automatic transmission equipped vehicles).
5. Water pump seal may run dry, increasing the risk of premature seal failure.
6. Combustion gas leaks into the coolant can also cause the above problems.

DEAERATION

As air is removed from the cooling system, it gathers in the coolant recovery container. This pressure is released into the atmosphere through the pressure valve located in the radiator pressure cap when pressure reaches 96 - 124 kPa (14 - 18 psi). This air is replaced with coolant from the coolant recovery container.

Note. Deaeration does not occur at engine idle, higher engine speeds are required. Normal driving will deaerate cooling system.

To effectively deaerate the system, multiple thermal cycles of the system may be required.

FLOW CHECK

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

1. If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If it is hot, coolant is circulating.
2. 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.

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.

1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be removed from pulleys (5 and 9).
2. Remove accessory drive belt (2).

DIESEL

1. Raise and support the vehicle. CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.
2. Using a wrench, rotate the belt tensioner (4) until the belt (3) can be removed from the pulleys (1, 2). Gently, release spring tension on tensioner (4).
3. Remove the accessory drive belt (3).

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

1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3).
2. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be installed on the generator pulley (3). Release spring tension onto accessory drive belt (2).

Note. When installing accessory drive belt, be sure belt is routed around all accessories correctly.

1. Install belt over all pulleys except for the power steering pump pulley. CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.
2. Using a wrench, rotate belt tensioner (4) clockwise until belt can be installed onto power steering pump pulley. Release spring tension onto belt.
3. Lower vehicle from hoist.

1. Position accessory drive belt tensioner (8) and install mounting bolt (1). Tighten bolt (1) to 24 N.m (212 in. lbs.).
2. Install accessory drive belt. Refer to «BELT, Serpentine, Installation»(ref-463907-S25546407892012041600000) . 1 - RIGHT MOUNT BOLT ACCESS PLUG 2 - FASCIA 3 - SPLASH SHIELD 4 - CRANKSHAFT BOLT ACCESS PLUG
3. Install belt splash shield (3).
4. Lower vehicle.

DIESEL ENGINE

1. Install tensioner pulley and bolt, if removed. Tighten bolt to 25 N.m (18 ft. lbs.).
2. From underneath the vehicle, position the belt tensioner assembly (4) onto the engine.
3. Install the lower bolt (3) into the accessory drive bracket to assist in holding the tensioner assembly (4) in place. Hand tighten the bolt.
4. Lower the vehicle.
5. Install the upper belt tensioner bolts (1, 2) to the accessory drive bracket. Tighten the bolts to 20 N.m (15 ft. lbs.).
6. Tighten the lower belt tensioner bolt to 45 N.m (33 ft. lbs.).
7. Install the accessory drive belt. Refer to «BELT, Serpentine, Installation»(ref-463907-S25546407892012041600000) .

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.

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).

1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps.
2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank.
3. Attach the adapter cone (2) to the vacuum gauge (1).
4. 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).
5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly.
6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
7. 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.
8. 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.
9. Close the vacuum generator/venturi ball valve.
10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly.
11. 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.
12. 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.
13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2).
14. Open the suction hose's ball valve to begin refilling the cooling system.
15. 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.
16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly.
17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank.
18. With heater control unit in the HEAT position, operate engine with container cap in place.
19. 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.
20. 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.
21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap.

Scheme 56

1. Remove the accessory drive belt. Refer to «BELT, Serpentine, Removal»(ref-463907-S04169480002012041600000) .
2. Raise vehicle. Refer to «Hoisting, Standard Procedure»(ref-463894-S05216189202012041600000) .
3. Remove accessory drive belt splash shield.
4. Drain cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
5. Remove screws attaching water pump pulley (1). Remove pulley (1).
6. Remove water pump mounting bolts (2).
7. Remove water pump (3).

Scheme 57

Scheme 58

Scheme 59

1. Disconnect and isolate the negative battery cable.
2. Drain the power steering fluid.
3. Raise and support the vehicle. NOTE: Drain the fluid in a clean container, free of debris. Save the fluid for re-use.
4. Drain the cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
5. Remove the accessory drive belt (1). Refer to «BELT, Serpentine, Removal»(ref-463907-S04169480002012041600000) .
6. Loosen the band clamps (4) and disconnect the coolant return hose from the water pump (3).
7. Remove the power steering line retaining bracket bolt (2).
8. Remove the coolant inlet hose (2) at the pump.
9. Remove the thermostat bypass hose at the pump.
10. Remove the power steering pump supply hose (1) at the pump.
11. Remove the power steering vacuum lines (3).
12. Disconnect the electronically controlled vacuum switch connector (4).
13. Remove the power steering pressure line (2).
14. Remove the water/power steering pump support bracket bolt.
15. Remove the water/power steering pump mounting bolts (1).
16. Remove the water/power steering pump (3).

Scheme 60

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle.
3. If equipped, remove the belly pan. NOTE: Drain the fluid in a clean container, free of debris. Save the fluid for re-use.
4. Drain the cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
5. Remove the coolant return hose to engine block bolt (2).
6. Loosen the band clamps and disconnect the coolant return hose from the water pump.
7. Loosen the band clamps and disconnect the coolant return hose from the cooling manifold (1).
8. Remove the coolant return hose (3).
9. Lower the vehicle.
10. Support the engine from underneath.
11. Remove the coolant recovery bottle. Refer to «BOTTLE, Coolant Recovery, Removal»(ref-463907-S06743019462012041600000) .
12. Remove the right side engine mount. Refer to «INSULATOR, Engine Mount, Right, Removal»(ref-463897-S23110733842012041600000) or «INSULATOR, Engine Mount, Right, Removal»(ref-463898-S24646221482012041600000) or «INSULATOR, Engine Mount, Right, Removal»(ref-463899-S15744441622012041600000) .
13. Raise the engine slightly on the right side enough to gain clearance to the cooling manifold mounting bolts (4).
14. Remove the cooling manifold mounting bolts (4).
15. Remove the cooling manifold (1) and gasket from the top of the vehicle.

Scheme 61

1. Remove the water pump assembly from the vehicle. Refer to «PUMP, Water, Removal»(ref-463907-S26682395342012041600000) or «PUMP, Water, Afterrun, Removal»(ref-463907-S41514956892012041600000) .
2. Discard the water pump outlet gasket (7).
3. Remove the three bolts (1) attaching the water pump pulley (2) to the water pump (4).
4. Remove the water pump pulley (2).
5. Remove the five bolts (3) attaching the water pump (4) to the water pump adapter (6).
6. Remove and discard the gasket (8).
7. Remove the water pump (4) and inspect carefully for any damage. Refer to «PUMP, Water, Inspection»(ref-463907-S14139596782012041600000) .

WATER PUMP

Replace water pump body assembly if it has any of these defects

1. Cracks or damage on the body.
2. Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body.
3. Loose or rough turning bearing.
4. Impeller rubs either the pump body or the engine block.
5. Impeller loose or damaged.
6. Sprocket or sprocket flange loose or damaged.

1. Position the water pump assembly (1) and gasket onto the cylinder block.
2. Position the water inlet tube (4) and gasket onto the water pump (1).
3. Install the mounting bolts (2). Tighten the bolts to 24 N.m (18 ft. lbs.).
4. Install the drive belt splash shield.
5. Lower the vehicle.
6. Install the accessory drive belt. Refer to «BELT, Serpentine, Installation»(ref-463907-S25546407892012041600000) .
7. Evacuate air and refill cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
8. Check cooling system for leaks. Refer to «Diagnosis and Testing»(ref-463907-S29320878212012041600000) .

1. Position the water/power steering pump (3) onto the engine block while guiding the thermostat bypass hose onto pump assembly.
2. Install the water/power steering pump mounting bolts (1). Tighten the bolts (1) to 20 N.M (15 ft. lbs.).
3. Install the water/power steering support bracket bolt. Tighten the bolt to 12 N.M (9 ft. lbs.).
4. Install the power steering pressure line (2). Tighten the nut to 32 N.M (24 ft. lbs.).
5. Connect the electronically controlled vacuum switch connector (4).
6. Connect the vacuum lines (3) to the electronically controlled vacuum switch.
7. Connect the coolant inlet hose (2) at the pump.
8. Connect the power steering pump supply hose (1) at the pump.
9. Connect the power steering pressure line retaining bracket bolt (2). Tighten the bolt to 12 N-m (9 ft. lbs.).
10. Connect the coolant return hose to the water pump (3). Tighten the band clamps (4) to 1.7 N-m (15 in. lbs.).
11. Install accessory drive belt (1). Refer to «BELT, Serpentine, Installation»(ref-463907-S25546407892012041600000) .
12. Lower the vehicle.
13. Evacuate air and refill cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
14. Fill and bleed the power steering system. Refer to «Standard Procedure»(ref-463902-S15628057832012041600000) .
15. Connect the negative battery cable.
16. Check cooling system for leaks. Refer to «Diagnosis and Testing»(ref-463907-S29320878212012041600000) .
17. Check the power steering system for leaks.

The coolant recovery system consists of a coolant recovery container mounted to the RH inner wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to the radiator neck, and a pressure cap.

The coolant recovery system consists of a coolant recovery container mounted to the RH inner wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to the radiator neck, and a pressure cap.

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

The location of the container allows any air or vapor exceeding the pressure/vent cap rating to escape through the cap. Coolant flows through the container at all times during engine operation whether the engine is cold or at normal operating temperature. The coolant container is equipped with a pressure/vent cap. For more information, refer to CAP, Radiator, Description .

Scheme 62

1. Partially drain cooling system using the draincock only. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) . Drain system below level of the coolant recovery pressure container.
2. Remove the return hose (5) from the upper radiator hose tee (3).
3. Remove the coolant recovery bottle mount bolt (2) from the mounting bracket (1).
4. Disengage the coolant recovery container (6) from the washer reservoir bottle (4).
5. Remove the coolant recovery container (6).

Scheme 63

1. Partially drain the cooling system using the draincock only. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) . Drain the system below the level of the coolant recovery pressure container (2).
2. Disconnect the return hose at the coolant recovery pressure container (2).
3. Remove the coolant recovery pressure container bolts.
4. Lift container up and disconnect the coolant hose (3) from the bottom of the pressure container (2).
5. Remove the pressure container (2) from engine compartment.

1. Position the coolant recovery container (6) into the washer fluid reservoir (4).
2. Install the coolant recovery container mounting bolt (2). Tighten the mounting bolt to 4 N.m (35 in. lbs.).
3. Connect the hose (5) at the upper radiator tee (3).
4. Fill coolant recovery container to proper level. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .

1. Lower the pressure container (2) into the engine compartment and connect the coolant hose (3) at bottom of the pressure container (2).
2. Position the pressure container (2) and install the mounting bolts. Tighten the mounting bolts to 4 N.m (35 lbs. in.).
3. Connect the coolant return hose to the coolant recovery container (2).
4. Refill the cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .

Scheme 64

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 (6) in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant recovery 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 65

All vehicles are equipped with a pressure cap. This cap releases pressure at some point within approximately 110 kPa (16 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 approximately 110 kPa (16 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.

Scheme 66

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.

If the pressure cap tests properly while positioned on Cooling System Tester (special tool #7700, Tester, Cooling System), 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

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.

HOAT COOLANT

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 base coolant with 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.

COOLANT PERFORMANCE

The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows

Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol, but this is not suitable for use in a cooling system. Water also freezes at a higher temperature, boils at a lower temperature and allows corrosion.

100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water.

COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar® Antifreeze/Coolant, 5 Year/100, 000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain 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.

Radiator fan operation is controlled by the Engine Control Module (ECM) with inputs from the temperature of the coolant, which is sensed by the coolant temperature sensor, and vehicle speed which is measured by the vehicle speed sensor. The ECM turns on the fan through either the high or low speed fan relay. The ECM provides a ground to the relay's control circuit. The fan relays are located on the back of the fan shroud.

If the cooling fan is inoperative or a Diagnostic Trouble Code (DTC) related to fan control has been set, for diagnostic procedures. Refer to appropriate powertrain control information. .

Radiator fan operation is controlled by the Totally Integrated Power Module (TIPM), with inputs from the engine coolant temperature sensor, continuously variable transmission (CVT) oil temperature, and A/C head pressure. The (TIPM) turns on the fan through either the high or low speed fan relay. The PCM provides a ground to the relay's control circuit. The fan relays are located in the (TIPM). Refer to the label beneath the (TIPM) cover for location of fan relays.

If the cooling fan is inoperative or a Diagnostic Trouble Code (DTC) related to fan control has been set, for diagnostic procedures. Refer to appropriate powertrain control information .

1. Install the lower air seal to radiator.
2. Position radiator into mounting position.
3. Position A/C condenser against radiator. Hand start fasteners.
4. Install radiator fan/shroud assembly. Hand start fasteners.
5. Tighten all condenser fasteners to 8 N.m (70 in. lbs.).
6. Tighten all radiator fan fasteners to 6 N.m (55 in. lbs.).
7. Install fasteners attaching transmission oil cooler to radiator. Tighten fasteners to 8 N.m (70 in. lbs.).
8. Raise vehicle on hoist.
9. Connect the lower air seal to the side air seals.
10. Connect lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.
11. Connect the radiator fan electrical connector.
12. Connect the power steering hoses.
13. Close radiator draincock.
14. Lower vehicle.
15. Connect upper radiator hose. Align the hose and position the clamp to prevent interference with the engine or hood.
16. Install upper radiator closure panel and center brace. Refer to «PANEL, Closure, Upper, Installation»(ref-463905-S02718099542012041600000) .
17. Install grille.
18. Install battery tray and battery.
19. Connect positive battery cable. Connect negative battery cable.
20. Install air cleaner housing assembly.
21. Fill cooling system with coolant. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
22. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

Note. Care must be taken not to damage the radiator cooling fins and tubes during installation.

1. Lower radiator into mounting position and reconnect Charge Air Cooler to radiator. Tighten bolts to 8 N.m (70 lbs. in.).
2. Position A/C condenser against radiator. Hand start lower fasteners.
3. Install radiator fan/shroud assembly. Hand start upper fasteners and remaining side fasteners that hold AC condenser.
4. Raise vehicle on hoist.
5. Connect charge air cooler hoses.
6. Install two remaining lower radiator fan shroud fasteners to radiator. Tighten fasteners to 6 N.m (55 in. lbs.).
7. If equipped, install fasteners attaching transmission oil cooler to radiator. Tighten fasteners to 8 N.m (70 in. lbs.).
8. Connect lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.
9. Connect the radiator fan motor electrical connector.
10. Close radiator draincock.
11. Lower vehicle.
12. Tighten radiator fan shroud fasteners to 6 N.m (55 in. lbs.).
13. Tighten AC condenser fasteners to 8 N.m (70 in. lbs.).
14. Install upper radiator hose. Align the hose and position the clamp to prevent interference with the engine or hood.
15. Install grille.
16. Install air cleaner housing assembly. Refer to «BODY, Air Cleaner, Installation»(ref-463897-S08564638532012041600000) or «BODY, Air Cleaner, Installation»(ref-463898-S05044287472012041600000) or «BODY, Air Cleaner, Installation»(ref-463899-S26434350682012041600000) .
17. Fill cooling system with appropriate coolant. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
18. Connect negative battery cable.
19. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

COOLANT ADAPTER MOUNTED

1. Lubricate the ECT sensor O-ring with coolant.
2. Install the ECT Sensor (1). Make sure the coolant sensor is locked in place.
3. Connect the ECT Sensor electrical connector.
4. Fill the cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
5. Connect the negative battery cable.

Scheme 67

1. Position and install coolant temperature sensor (5).
2. Connect coolant temperature sensor electrical connector. 1 - RETAINING CLAMP 2 - ENGINE COOLANT TEMPERATURE SENSOR
3. Refill coolant system to proper level with proper mixture of coolant. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
4. Install engine cover. Refer to «Installation»(ref-463897-S39304967882012041600000) or «Installation»(ref-463898-S11781531982012041600000) or «Installation»(ref-463899-S06345110712012041600000) .
5. Connect negative battery cable. WARNING: Use extreme caution when engine is operating. Do not stand in a direct line with fan. Do not put your hands near pulleys, belts or fan. Do not wear loose clothes.
6. Start engine and inspect for leaks.

Scheme 68

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.

SECONDARY THERMOSTAT - GAS ENGINE

1. Position the thermostat into the cylinder head.
2. Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter. Replace O-ring as necessary.
3. Lubricate the O-rings with soapy water.
4. Position the coolant adapter on the water pump inlet tube and the cylinder head.
5. Install the coolant adapter mounting bolts. Tighten the bolts to 18 N.m (159 in. lbs.).
6. Connect the front coolant hose (1).
7. Connect the two rear coolant hoses (1).
8. Connect the radiator hose (3).
9. Install the air filter housing Refer to «BODY, Air Cleaner, Installation»(ref-463897-S08564638532012041600000) or «BODY, Air Cleaner, Installation»(ref-463898-S05044287472012041600000) or «BODY, Air Cleaner, Installation»(ref-463899-S26434350682012041600000) .
10. Fill the cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .

Check the external cooler for debris on the cooling fin surfaces. Clean as necessary.