Engine Cooling System: Removal & Installation Dodge Caliber I рестайлинг

REMOVAL

1. Raise vehicle on hoist.
2. Remove belt splash shield.
3. Remove accessory drive belt. Refer to «BELT, Serpentine, Removal»(ref-463907-S04169480002012041600000) .
4. Remove idler pulley mounting bolt. Remove idler pulley (5 or 9).

2.2L IDLER PULLEYS - REMOVAL

1. Remove the accessory drive belt (3). Refer to «BELT, Serpentine, Removal»(ref-463907-S04169480002012041600000) .
2. From under the vehicle, remove the idler pulley mounting bolt. Remove idler pulley (2).

INSTALLATION

1. Position pulley (5 or 9) in mounting position. Install idler pulley mounting bolt. Tighten bolt to 48 N.m (35 ft. lbs.).
2. Install accessory drive belt. Refer to «BELT, Serpentine, Installation»(ref-463907-S25546407892012041600000) .
3. Install belt splash shield.
4. Lower vehicle.

2.2L IDLER PULLEYS - INSTALLATION

1. Position and install the idler pulley and bolt (2) from under the vehicle. Tighten bolt to 25 N.m (18 ft. lbs.).
2. Install the accessory drive belt. Refer to «BELT, Serpentine, Installation»(ref-463907-S25546407892012041600000) .

ACCESSORY DRIVE BRACKET INSTALLATION - DIESEL ENGINE

1. If necessary, install the thermostat (2) to the accessory drive bracket (1).
2. Position the accessory drive bracket (1) to the engine.
3. Install the accessory drive bracket mounting bolts. Tighten the bolts to 9 N-m (80 in. lbs.).
4. Install the thermostat housing mounting bolts. Tighten the bolts to 9 N-m (80 in. lbs.).
5. Install the radiator hose (3) to the thermostat housing (2).
6. Install the coolant bypass hose to the thermostat housing (2).
7. Install the accessory drive belt tensioner. Refer to «TENSIONER, Belt, Installation»(ref-463907-S25499571432012041600000) .
8. Install the EGR cooler. Refer to «COOLER, EGR, Installation»(ref-463907-S03371209622012041600000) .
9. Install the generator. Refer to «GENERATOR, Installation»(ref-463919-S38979133722012041600000) .
10. Install the A/C compressor. Refer to «COMPRESSOR, A/C, Installation»(ref-463903-S21698286882012041600000) .
11. Install the A/C condenser. Refer to «CONDENSER, A/C, Installation»(ref-463903-S32252423332012041600000) .
12. Install the charge air cooler.
13. Install the coolant recovery bottle. Refer to «BOTTLE, Coolant Recovery, Installation»(ref-463907-S15209862532012041600000) .
14. Install the water/power steering/vacuum pump assembly. Refer to «PUMP, Water, Installation»(ref-463907-S24334832082012041600000) or «PUMP, Water, Afterrun, Installation»(ref-463907-S06641562992012041600000) .
15. Install the negative battery cable.

Scheme 30

The water pump (3) on the world engine is attached to the water pump adapter on the front of the cylinder block.

The water pump is driven by the accessory drive belt. The water pump is connected to the water plenum by the return tube.

Scheme 31

The combination water/power steering pump (1) on this vehicle is attached to the lower corner of the cylinder block on the left hand side.

The water/power steering pump (1) cannot be disassembled or serviced separately.

The water/power steering pump (1) is driven by the accessory drive's serpentine belt.

Scheme 32

The water pump is turned on or off by vacuum. The ECM (Engine Control Module) actuates a switchover valve that turns vacuum supply to the water pump piston. A piston slides back and forth covering and uncovering a port used for coolant flow.

The controlling of the coolant flow helps manage temperature throughout the cooling system.

The water pump can be shut off if the following conditions exist

1. Engine speed is not achieved
2. The fuel injection quantity in not achieved
3. Intake air temperature is not reached
4. Coolant temperature is not reached
5. The A/C control unit does not request the heating mode

1. Align draincock stem to radiator tank opening.
2. Push draincock (2) into the radiator tank opening.
3. Tighten the draincock (2) by turning clockwise until it stops.
4. Fill the cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
5. Install front passenger side splash shield assembly to the wheelhouse area. Refer to «SHIELD, Splash, Front Wheel House, Installation»(ref-463905-S25620980292012041600000) .
6. Install the front passenger side wheel.

COOLING FAN - REMOVAL

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Remove the air intake duct.
2. Disconnect negative cable from battery.
3. Drain the coolant just below the upper radiator hose.
4. Remove the upper radiator closure panel (2). Refer to «PANEL, Closure, Upper, Removal»(ref-463905-S32441417902012041600000) .
5. Remove the hood latch cable.
6. Remove the upper core support seal push pins (3).
7. Remove radiator core support bolts (1).
8. Remove the upper radiator hose support bracket (2).
9. Remove the upper radiator hose from the radiator and position aside.
10. Remove the wiring harness from the fan shroud.
11. Disconnect radiator fan electrical connectors.
12. Remove radiator fan module (1) by lifting up from the engine compartment.
13. Remove the lower (8) shroud seal.
14. Remove the fan blade retaining nut (4) from the fan motor.
15. Remove the fan motor (5) assembly from the shroud.

COOLING FAN - INSTALLATION

1. Install the fan motor (5) onto shroud (3).
2. Install the fan (6) onto the motor.
3. Install the lower (8) shroud seal.
4. Install radiator fan module (1).
5. Connect the electrical connectors.
6. Install the wiring harness mounting retainers into fan shroud.
7. Install the upper radiator hose support bracket (2).
8. Install upper radiator hose to the radiator.
9. Install the upper radiator core support. Tighten outer bolts (1) to 23 N.m (17 ft. lbs.). Tighten the inner support bolts to 8 N.m (6 ft. lbs.).
10. Install the hood latch cable.
11. Install the core support seal (3).
12. Install radiator closure panel (2). Refer to «PANEL, Closure, Upper, Installation»(ref-463905-S02718099542012041600000) .
13. Connect the negative battery cable.
14. Fill the coolant to the proper level.
15. Run vehicle. Check for proper fan operation and coolant level.
16. Install the air intake duct.

Scheme 37

The cartridge type block heater is mounted in a bore at the rear of the block under the coolant adapter. The block heater does not directly contact coolant. It heads the aluminum block.

The heater is powered by 110 Volt AC through a power cord and connector.

1. Thoroughly clean bore hole.
2. Insert block heater assembly into bore.
3. Install retaining clip.
4. Connect power cord to block heater.
5. Install air intake inlet.
6. Install engine cover.

Scheme 38

1. Disconnect and isolate the negative battery cable.
2. Partically drain cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
3. Remove the air cleaner housing. Refer to «BODY, Air Cleaner, Removal»(ref-463897-S39248803232012041600000) or «BODY, Air Cleaner, Removal»(ref-463898-S09866072732012041600000) or «BODY, Air Cleaner, Removal»(ref-463899-S08239213792012041600000) .
4. Disconnect the after run pump electrical connector.
5. Remove the coolant hoses from the after run pump.
6. Remove the after run pump from the vehicle.

1. Position the after run pump (2) onto the mounting brcaket (3).
2. Connect the two coolant hoses (4) to the after run pump (2).
3. Connect the after run pump electrical connector (1).
4. Install the air cleaner 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) .
5. Install the negative battery cable.
6. Fill the cooling system Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .

ENGINE COOLANT THERMOSTAT INSTALLATION - DIESEL ENGINE

Note. Use coolant on the seals of the thermostat housing so the seals wont become damaged and to help aid in installation.

1. Install the thermostat housing (2) into the accessory carrier bracket (1) by using hand pressure and twisting motion to seat the housing into place.
2. Install the two thermostat housing mounting bolts (2). Tighten the bolts to 9 N-m (80 in. lbs.).
3. Connect the thermostat heater connector (1).
4. Install the EGR (3) and the inlet nozzle (1). Install two bolts (2) to support nozzle and EGR in place. Do not tighten.
5. Raise vehicle.
6. Install all mounting screws (2) for the EGR throttle control housing and the inlet nozzle, to the mixing tank. Tighten bolts (2) to 9 N.m (80 in. lbs.).
7. Install the brake booster check valve vacuum line at the pump.
8. Install the water/power steering pump assembly. Refer to «PUMP, Water, Installation»(ref-463907-S24334832082012041600000) or «PUMP, Water, Afterrun, Installation»(ref-463907-S06641562992012041600000) .
9. Install the main drive belt (3).
10. Lower vehicle.
11. Install lower thermostat housing hose clamp onto combination water/power steering pump.
12. Connect the EGR throttle control and charge air temperature sensor connectors (1).
13. Install the upper brake booster vacuum line bracket bolt (1).
14. Install the front lower air charge hose (2). Tighten hose clamps to 1.7 N.m (15 in. lbs.).
15. Install the front upper air charge hose (1). Tighten hose clamps to 1.7 N.m (15 in. lbs.).
16. Install the fan module assembly. Refer to «FAN, Cooling, Installation»(ref-463907-S39335225802012041600000) .
17. Add coolant. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
18. Add power steering fluid. Refer to «Standard Procedure»(ref-463902-S15628057832012041600000) .
19. Connect the negative battery cable.
20. Run engine to operating temperature and check for leaks.

Scheme 39

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.

1. Drain cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .
2. Remove the coolant adapter and secondary thermostat. Refer to «THERMOSTAT, Removal»(ref-463907-S41319135622012041600000) .
3. Raise and support vehicle.
4. Remove inlet tube mounting nuts (1).
5. Remove inlet tube (2).

1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary.
2. Lubricate O-rings with soapy water.
3. Install new water inlet gasket between tube and water pump housing (2).
4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment.
5. Install secondary thermostat and coolant adapter. Refer to «THERMOSTAT, Installation»(ref-463907-S05509166812012041600000) .
6. Tighten coolant tube nuts (1) to 24 N.m (212 in. lbs.).
7. Fill cooling system. Refer to «Standard Procedure»(ref-463907-S41979752222012041600000) .

Scheme 40

The automatic transmission cooler is located in the front of the radiator and behind the front fascia and is combined with the A/C condenser. The transmission cooler is a heat exchanger that allows heat in the transmission fluid to be transferred to the air passing over the cooler fins.

The Transmission oil cooler/A/C condenser assembly is equipped with quick connect fitting for the transmission oil cooler lines.

Scheme 41

1. On models equipped with A/C, refer to the A/C Condensor removal procedures. Refer to «CONDENSER, A/C, Removal»(ref-463903-S11301123012012041600000) .
2. On non A/C equipped models, lift the vehicle and remove the lower closeout panel.
3. Using Tool (special tool #8875A, Disconnect, Transmission Cooler Line) disconnect the transmission cooler lines (1) from the transmission oil cooler (3). Refer to «TUBES AND HOSES, Transmission Oil Cooler, Standard Procedure»(ref-463907-S16085832532012041600000) .
4. Remove the transmission oil cooler mounting bolts (2).
5. Remove the transmission oil cooler (3).

1. On models equipped with A/C, refer to the A/C Condensor installation procedure. Refer to «CONDENSER, A/C, Installation»(ref-463903-S32252423332012041600000) .
2. On non A/C equipped models, position the transmission oil cooler (3) to the radiator.
3. Install the transmission oil cooler mounting bolts (2). Tighten the bolts to 8 N.m (70 in. lbs.).
4. Connect the transmission cooler lines to the transmission oil cooler (1). Refer to «TUBES AND HOSES, Transmission Oil Cooler, Standard Procedure»(ref-463907-S16085832532012041600000) .
5. Install the lower closeout panel.
6. Lower the vehicle.
7. Start engine and check transmission fluid level. Adjust level as necessary.

Scheme 42

1. Remove the dust cap by pulling it straight back off of the quick connect fitting (1).
2. Place the properly sized release tool (4) onto the transmission cooler line with the fingers of the tool facing the quick connect fitting.
3. Slide the 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.
4. Rotate the release tool 60° to expand the retaining clip.
5. While holding the release tool against the quick connect fitting, pull back on the transmission cooler line to remove it.
6. If the quick connect fitting is damaged or leaking at the transmission oil cooler or transmission, remove the fitting.

Scheme 43

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

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