Engine Cooling System: Other Dodge Challenger III

GASOLINE ENGINE

The cooling system consists of

1. Radiator
2. Electric Cooling fan
3. Fan shroud
4. Radiator pressure cap
5. Thermostat
6. Coolant recovery container
7. Transmission oil cooler (if equipped with an automatic transmission)
8. Coolant
9. Water pump
10. Hoses and hose clamps

GASOLINE ENGINES

The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible. It also maintains normal operating temperature and prevents overheating.

Scheme 29

The cooling system also provides a means of heating the passenger compartment and cooling the automatic transmission fluid (if equipped).

Scheme 30

The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system.

LEAKS

Scheme 31

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) (1). Pour one ounce of additive into cooling system. Place heater control unit in HEAT position. Start and operate engine until the 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 the additive to glow a bright green color.

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

Scheme 32

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

Carefully remove the radiator pressure cap from the filler neck and check coolant level. Push down on cap to disengage it from the stop tabs. Wipe the inside of filler neck and examine the lower inside sealing seat for nicks, cracks, paint, dirt and solder residue. Inspect the 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 the outside of filler neck. If the cams are damaged, seating of the pressure cap valve and tester seal will be affected.

Attach pressure tester (7700 or an equivalent) (1) to radiator filler neck.

Operate tester pump to apply 124.1 kPa (18 psi) pressure to system. If hoses enlarge excessively or bulge while testing, replace as necessary. Observe the gauge pointer and determine the condition of the cooling system according to the following criteria

Holds Steady: If the 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. Refer to INTERNAL LEAKAGE INSPECTION .

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.

TRAILER TOWING

Consult Trailer Towing section of owners manual. Do not exceed limits.

RECENT SERVICE OR ACCIDENT REPAIR

Determine if any recent service has been performed on vehicle that may effect cooling system. This may be

1. Engine adjustments (incorrect timing)
2. Slipping engine accessory drive belt(s)
3. Brakes (possibly dragging)
4. Changed parts. Incorrect water pump or pump rotating in wrong direction due to belt not correctly routed
5. 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 COOLING SYSTEM DIAGNOSIS CHART BELOW.

These charts are to be used as a quick-reference only. Refer to COOLING SYSTEM DIAGNOSIS CHART .

COOLING SYSTEM DIAGNOSIS CHART

Scheme 33

Note. Typical drain plug shown in illustration.

DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse.

Scheme 34

1. Remove radiator pressure cap.
2. Raise and secure vehicle.
3. If equipped, remove the underbody splash shield.
4. Loosen radiator petcock.
5. Drain coolant into a clean container.
6. If necessary, to perform a complete coolant drain of the engine, remove the drain plug (1) from the engine block.

Scheme 35

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. In order to maintain the required protection for these components and cooling system performance, only use the appropriate fluid. Refer to Vehicle Quick Reference/Capacities and Recommended Fluids - Description when servicing the vehicle. This coolant offers the best engine cooling without corrosion when mixed with 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.

Note. Cooling system fill procedure is critical to overall cooling system performance.

1. Close radiator draincock. Hand tighten only.
2. Install engine block drain plugs, if removed. Coat the threads with Mopar® Thread Sealant with Teflon. WARNING: When installing drain hose to air bleed valve, route hose away from accessory drive belts, accessory drive pulleys, and electric cooling fan motors. NOTE: It may be necessary to install a bleed fitting on the 5.7L engine.
3. Attach a 1.5 - 2 m (4 - 6 ft.) long 6.35 mm (1/4 inch.) ID clear hose to bleeder fitting Bleed Valve Location (2.7L): Located on the water outlet connector at the front of engine. Bleed Valve Location (3.5L): Located on the lower intake manifold, left of center and below the upper intake plenum. Plug Location (5.7L/6.1L): Located on the front of the water outlet housing at the front of engine.
4. Route hose (2) away from the accessory drive belt, drive pulleys and electric cooling fan. Place the other end of hose (2) into a clean container. The hose will prevent coolant from contacting the accessory drive belt when bleeding the system during the refilling operation. NOTE: It is imperative that the cooling system air bleed valve be opened before any coolant is added to the cooling system. Failure to open the bleed valve first will result in an incomplete fill of the system.
5. 5.7L/6.1L ENGINE - Install a threaded and barbed fitting (1/4 - 18 npt) into water pump housing.
6. Attach Tool 8195, Filling Aid Funnel to pressure bottle filler neck.
7. Using hose pinch-off pliers, pinch overflow hose (3) that connects between the two chambers of the coolant bottle (2).
8. Open bleed fitting. CAUTION: Do not mix coolants. If coolant is used other than specified, a reduction in corrosion protection will occur.
9. Pour the antifreeze mixture. Refer to «Vehicle Quick Reference/Capacities and Recommended Fluids - Description»(ref-353986-S32118756712010011300000) into the larger section of Filling Aid Funnel (the smaller section of funnel is to allow air to escape). For system capacity. See «Cooling - Specifications»(ref-353989-S35736081782010011300000) .
10. Slowly fill the cooling system until a steady stream of coolant flows from the hose attached to the bleed valve.
11. Close the bleed valve and continue filling system to the top of the Tool 8195, Filling Aid Funnel.
12. Remove pinch-off pliers from overflow hose.
13. Allow the coolant in Filling Funnel to drain into overflow chamber of the pressure bottle.
14. Remove Tool 8195, Filling Aid Funnel. Install cap on coolant pressure bottle.
15. Remove hose from bleed valve.
16. 5.7L/6.1L ENGINE - Install fitting into thermostat housing. Coat the threads with Mopar® Thread Sealant with Teflon.
17. Start engine and run at 1500 - 2000 RPM for 30 minutes. NOTE: The engine cooling system will push any remaining air into the coolant bottle within about an hour of normal driving. As a result, a drop in coolant level in the pressure bottle may occur. If the engine cooling system overheats and pushes coolant into the overflow side of the coolant bottle, this coolant will be sucked back into the cooling system ONLY IF THE PRESSURE CAP IS LEFT ON THE BOTTLE. Removing the pressure cap breaks the vacuum path between the two bottle sections and the coolant will not return to cooling system.
18. Shut off engine allow it to cool down for 30 minutes. This permits coolant to be drawn into the pressure chamber.
19. With engine COLD, observe coolant level in pressure chamber. Coolant level should be within MIN and MAX marks. Adjust coolant level as necessary. NOTE: The coolant bottle has two chambers. Coolant will normally only be in the inboard of the two. The outboard chamber is only to recover coolant in the event of an overheat or after a recent service fill.

ADDING ADDITIONAL COOLANT

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.

Scheme 36

Note. Do not remove radiator cap for routine coolant level inspections. The coolant level can be checked at coolant recovery bottle (2).

The coolant reserve/overflow system provides a quick method for determining coolant level. With engine not running, the coolant level should be between MIN and MAX marks (3). If the coolant level is at or below the MIN mark, fill the recovery bottle with a 50/50 mixture of antifreeze and water ONE QUART AT A TIME. Repeat this procedure until the coolant level is at the FULL mark.

CLEANING

Drain cooling system and refill with water. Run engine with radiator cap installed until upper radiator hose is hot. Stop engine and drain water from system. If water is dirty, fill system with water, run engine and drain system. Repeat until 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.

Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt.

3.5L

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.
2. Position accessory drive belt around all pulleys except the idler pulley (1). Rotate the tensioner arm (5) until it contacts it's stop position. Route the accessory drive belt around the idler (1) and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys. NOTE: NOTE: ON all engines, the tensioner (5) is equipped with an indexing tang on back of tensioner and an indexing stop on tensioner housing. If a new belt is being installed, tang must be within approximately 6 - 8mm (0.24 - 0.32 in.) of indexing stop (i.e. tang is approximately between the two indexing stops). Belt is considered new if it has been used 15 minutes or less.
3. With the drive belt installed, inspect the belt wear indicator.

5.7L

1. Position the accessory drive belt (4) over all pulleys except for the water pump pulley (8).
2. Rotate the tensioner (7) clockwise and slip the accessory drive belt over the water pump pulley (8).
3. Gently release the tensioner (7).
4. Install the air intake tube between the intake manifold and air filter assembly.

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.
2. Position accessory drive belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the accessory drive belt around the idler and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys.
3. With the accessory drive belt installed, inspect the belt wear indicator.

Scheme 38

1. Remove accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353989-S00873162722010011300000) .
2. Remove cover (3).
3. Remove bolt (2) and idler pulley (1).

Scheme 39

1. Remove accessory drive belt. See «Cooling/Accessory Drive/TENSIONER, Belt - Removal»(ref-353989-S25288318732010011300000) .
2. Remove cover (3).
3. Remove bolt (2) and idler pulley (1).

Scheme 40

1. Position idler pulley (1).
2. Tighten bolt to (2) 28 N.m (250 in. lbs.).
3. Install cover (3).
4. Install accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .

Scheme 41

1. Position idler pulley (1).
2. Tighten bolt (2) to 54 N.m (40 ft. lbs.).
3. Install cover (3).
4. Install accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .

Scheme 42

Correct drive belt tension is required to ensure optimum performance of the belt (1) driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life.

1. Install the accessory drive belt tensioner on to the mounting bracket. Tighten the bolt to 41 N.m (30 ft. lbs.).
2. Install accessory drive belt tensioner and bracket assembly
3. Install the accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .

Scheme 43

1. Install tensioner bolt (2) to tensioner (1). Tighten bolt to 34 N.m (40 ft. lbs.).
2. Install accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .
3. Check belt indexing marks.

Scheme 44

1. Partially drain cooling system using the draincock only. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) . Drain system below level of the coolant recovery pressure container.
2. Remove coolant recovery container pressure cap (4).
3. Remove and plug coolant recovery tube (1).
4. Remove mounting nuts (2).
5. Remove coolant recovery container (3) from vehicle.

RADIATOR CAP-TO-FILLER NECK SEAL

The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 124 kPa (18 psi) and hold pressure at a minimum of 110 kPa (186psi).

Do not remove radiator cap at any time except for the following purposes

1. Check and adjust antifreeze freeze point.
2. Refill system with new antifreeze.
3. Conducting service procedures.
4. Checking for vacuum leaks. WARNING: If vehicle has been run recently, wait at least 15 minutes before removing radiator cap. With a rag, squeeze radiator upper hose to check if system is under pressure. Place a rag over cap and without pushing cap down, rotate it counter-clockwise to first stop. Allow fluid to escape through the coolant reserve/overflow hose into reserve/overflow tank. Squeeze radiator upper hose to determine when pressure has been released. When coolant and steam stop being pushed into tank and system pressure drops, remove radiator cap completely.

Scheme 45

Remove cap (1) from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install cap (1) on pressure tester 7700 (2) or an equivalent.

Operate tester pump to bring pressure to 124 kPa (18 psi) on gauge. If pressure cap (1) fails to hold pressure of at least 110 kPa (16 psi) replace cap. Refer to the following CAUTION .

The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly.

Use only a mild soap and water to clean the radiator cap. Using any type solvent may cause damage to the seal in the radiator cap.

GAS 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.

DIESEL ENGINE

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. Glysantin G 30-91 Antifreeze/Coolant, 5 Year/150,000 Mile Formula (ASTM D3306), or the equivalent ethylene glycol based coolant. This coolant offers the best engine cooling without corrosion when mixed with 50% coolant and 50% distilled water to obtain a freeze point of -36°C (-34°F). It is dyed purple to distinguish it's unique chemistry from traditional green and yellow silicate coolants. If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

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

ENGINE BLOCK HEATER

If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110-volt test light; test heater element continuity with an ohmmeter or 12-volt test light.

Scheme 46

1. Raise vehicle on hoist.
2. Detach power cord plug from block heater (1).
3. Remove block heater attaching screw located below heater terminals.
4. Remove block heater from cylinder block (2).

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

6.1L

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

Scheme 47

1. Thoroughly clean cylinder block heater cavity.
2. Insert heater assembly (1) into block (2) with mounting hole is located below heater terminals.
3. Install mounting screw and tighten to 12 N.m (105 in. lbs.).
4. Attach power cord to heater. CAUTION: To prevent damage, the power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds.
5. Lower vehicle.

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

5.7L/6.1L ENGINE

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

Scheme 48

The 3.5L water pump has a die cast aluminum housing (3) and a plastic swept vane impeller (2) and bolts directly to the rear timing belt cover using a press-in-place gasket (1) for sealing. The water pump is driven by the engine timing belt.

Scheme 49

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).

Scheme 50

Scheme 51

Scheme 52

Scheme 53

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 have collapsed.
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 54

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

1. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
2. Remove accessory drive belts. See «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353989-S00873162722010011300000) .
3. Remove engine timing belt. Refer to «Engine/Valve Timing/BELT and SPROCKETS, Timing - Removal»(ref-354006-S33158074632010011300000) .
4. Remove water pump mounting bolts (3). Note position of longer bolts for proper reinstallation.
5. Remove water pump body from engine.

Scheme 55

1. Disconnect the negative battery cable.
2. Drain the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove the fan/viscous fan drive assembly from the water pump. See «Cooling/Engine/FAN, Cooling - Removal»(ref-353989-S00522577462010011300000) . Do not attempt to remove the 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.
5. Remove the two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector.
6. Remove the fan shroud and the fan blade/viscous fan drive assembly from the vehicle.
7. Remove A/C compressor and generator brace.
8. Remove idler pulleys. See «Cooling/Accessory Drive/PULLEY, Idler - Removal»(ref-353989-S06757068742010011300000) .
9. Remove the belt tensioner assembly. See «Cooling/Accessory Drive/TENSIONER, Belt - Removal»(ref-353989-S25288318732010011300000) .
10. Remove the upper and lower radiator hoses.
11. Remove the heater hoses.
12. Remove the water pump mounting bolts and remove the pump.

Scheme 56

1. Disconnect negative battery cable.
2. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove radiator fan assembly. See «Cooling/Engine/FAN, Cooling - Removal»(ref-353989-S00522577462010011300000) .
4. Remove accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353989-S00873162722010011300000) .
5. Remove thermostat. See «Cooling/Engine/THERMOSTAT - Removal»(ref-353989-S32488018602010011300000) . NOTE: The water pump mounting bolts (2) are different lengths. Note the location of the water pump mounting bolts (2).
6. Remove water pump mounting bolts (2) and remove water pump (1).

WATER PUMP

Inspect and replace the water pump if it has any of the following defects

Scheme 57

Scheme 58

1. Damage or cracks on the pump body. 1 - THERMOSTAT HOUSING/COOLANT INLET 2 - BOLT 3 - NUT 4 - WEEP HOLE
2. Coolant leaks: If the shaft seal is leaking, this will be evident by traces of thick deposits of dried glycol running down from the pump primary weep passage. A thin black stain below the pump primary weep hole/passage is considered normal operation. 1 - WEEP PASSAGE TO VALLEY OF BLOCK 2 - HOLE IN REAR OF BLOCK
3. Coolant leaks: If the pump primary weep passage is plugged, coolant may come from the secondary weep passage and collect in the valley of the engine. The coolant will eventually run out the back side of the engine. Leakage from the secondary weep passage may give false indications that core plug(s) may be leaking on the back side of the engine block. If this condition is found, clean the primary weep passage of debris. NOTE: It is normal for the water pump to weep a small amount of coolant from the primary weep hole (black stain at weep passage). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident from the primary weep passage. This indicates a shaft seal failure and pump must be replaced. Coolant may leak from the secondary weep passage and fill the valley of the engine. If this condition is found, clean the primary weep passage of debris. Be sure to perform a thorough analysis before replacing water pump.
4. Impeller rubs inside of cylinder block.
5. Excessively loose or rough turning bearing.

3.5L ENGINE

1. Clean all O-ring surfaces on front cover.
2. Position water pump and O-ring to engine.
3. Install mounting bolts (3). Tighten to 12 N.m (105 in. lbs.).
4. Install timing belt. Refer to «Engine/Valve Timing/BELT and SPROCKETS, Timing - Installation»(ref-354006-S16397826472010011300000) .
5. Install accessory drive belts. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .
6. Evacuate air and refill cooling system. See «Cooling/Engine/PUMP, Water - Standard Procedure»(ref-353989-S17408123952010011300000) .
7. Check cooling system for leaks. See «Cooling - Diagnosis and Testing»(ref-353989-S06225083732010011300000) .

1. Install the water pump and the mounting bolts. Tighten mounting bolts to 24 N.m (18 ft. lbs.).
2. Install the heater hoses.
3. Install the upper and lower radiator hoses.
4. Install the accessory drive belt tensioner assembly. See «Cooling/Accessory Drive/TENSIONER, Belt - Installation»(ref-353989-S37593874422010011300000) .
5. Install the idler pulleys and mounting bolts. Tighten the bolts to 54 N.m (40 ft. lbs.).
6. Install the A/C compressor and the alternator brace. Tighten bolt and nuts to 28 N.m (21 ft. lbs.).
7. Install the fan shroud assembly and two fan shroud mounting screws.
8. Install the fan/viscous drive assembly. See «Cooling/Engine/FAN, Cooling - Installation»(ref-353989-S05750560782010011300000) .
9. Make sure there is at least 25 mm (1.0 inches) between the tips of the fan blades and the fan shroud.
10. Install the accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .
11. Connect the negative battery cable.
12. Evacuate air and refill cooling system. See «Cooling/Engine/PUMP, Water - Standard Procedure»(ref-353989-S17408123952010011300000) .
13. Check cooling system for leaks. See «Cooling - Diagnosis and Testing»(ref-353989-S06225083732010011300000) .

1. Install water pump and mounting bolts (2). Tighten mounting bolts to 28 N.m (20 ft. lbs.).
2. Make sure double ended bolt (3) is in the proper location. Tighten double ended bolt to 28 N.m (20 ft. lbs.).
3. Install thermostat. See «Cooling/Engine/THERMOSTAT - Installation»(ref-353989-S00045707752010011300000) .
4. Install accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Installation»(ref-353989-S17064831522010011300000) .
5. Install the radiator fan assembly. See «Cooling/Engine/FAN, Cooling - Installation»(ref-353989-S05750560782010011300000) .
6. Connect negative battery cable.
7. Evacuate air and refill cooling system. See «Cooling/Engine/PUMP, Water - Standard Procedure»(ref-353989-S17408123952010011300000)
8. Check cooling system for leaks. See «Cooling - Diagnosis and Testing»(ref-353989-S06225083732010011300000)

Scheme 59

Scheme 60

Scheme 61

1. Disconnect negative battery cable.
2. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove upper radiator hose (2).
4. Remove upper radiator closure panels (1).
5. Remove radiator fan assembly (4). See «Cooling/Engine/FAN, Cooling - Removal»(ref-353989-S00522577462010011300000) . 1 - LOWER RADIATOR HOSE 2 - RADIATOR FAN ASSEMBLY
6. Raise vehicle.
7. Remove lower splash shield.
8. Remove lower radiator hose (1).
9. Remove lower condenser mount bolts.
10. Lower vehicle.
11. Remove upper radiator hose. CAUTION: Bolts are installed with threadlocker. Use hand tools to remove the upper radiator mounting bolts.
12. Remove upper radiator mounting brackets (1) and bolts (2).
13. Remove upper condenser mounting bolts.
14. Separate condenser assembly from radiator.
15. Tilt radiator toward engine and remove radiator from vehicle.

Clean radiator fins are necessary for good heat transfer. The radiator and air conditioning fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.

1. Install engine coolant temperature sensor (2). Tighten sensor to 28 N.m (20 ft. lbs.).
2. Attach electrical connector to sensor.
3. Connect negative battery cable.

Scheme 62

1. Apply thread sealant to ECT sensor threads.
2. Install the ECT sensor (3) to the engine.
3. Tighten the ECT sensor to 11 N.m (97.3 in. lbs.).
4. Connect the electrical connector (2).
5. Fill the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .

Scheme 63

1. Apply thread sealant to sensor threads.
2. Install ECT sensor (3) to engine.
3. Tighten sensor to 11 N.m (98 in. lbs.).
4. Connect electrical connector (2) to ECT sensor (3).
5. Fill the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .

ENGINE COOLANT THERMOSTAT

The thermostat is operated by a wax filled chamber (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver.

Thermostat diagnostics is included in powertrain control module's (PCM) programing for on-board diagnosis. The malfunction indicator light (MIL) will illuminate and a diagnostic trouble code (DTC) will be set when an "open too soon" condition occurs. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. For other probable causes. See Cooling - Diagnosis and Testing . Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. See Cooling - Diagnosis and Testing .

Scheme 64

1. Disconnect negative battery cable.
2. Raise vehicle on hoist.
3. Remove belly pan. Refer to «Body/Exterior/BELLY PAN - Removal»(ref-353987-S28210114602010011300000) .
4. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
5. Lower vehicle on hoist.
6. Remove air box assembly. Refer to «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-354006-S27420535772010011300000) .
7. Disconnect lower radiator hose (2) from thermostat housing (1).
8. Remove thermostat housing bolts.
9. Remove thermostat housing (1), thermostat, and gasket. NOTE: The OEM thermostat is staked in place at the factory. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the thermostat housing using a suitable hand held grinder. It is not necessary to restake the replacement thermostat into the thermostat housing.
10. Clean gasket surfaces.

Scheme 65

1. Disconnect the negative battery cable.
2. Drain the cooling system until the coolant level is below the thermostat. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove the radiator hose (3) from the thermostat housing (1).
4. Remove the thermostat housing mounting bolts (2), thermostat housing (1), and thermostat.

Scheme 66

1. Disconnect negative battery cable at battery.
2. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove radiator hose at thermostat housing (1). NOTE: Thermostat o-ring is part of thermostat (2) and is not serviced separately.
4. Remove thermostat housing mounting bolts (3), thermostat housing (1) and thermostat (2).

1. Position gasket on thermostat and housing (1).
2. Install thermostat housing (1), gasket and mounting bolts onto block. Tighten attaching bolts to 12 N.m (105 in. lbs.).
3. Install radiator hose (2).
4. Install air box assembly. Refer to «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-354006-S05303918372010011300000)
5. Fill cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
6. Raise vehicle on hoist.
7. Install belly pan. Refer to «Body/Exterior/BELLY PAN - Installation»(ref-353987-S05996027422010011300000)
8. Connect negative battery cable.

1. Clean the mating areas of the intake manifold and thermostat housing (1).
2. Install the thermostat into the recessed machined groove on the front cover.
3. Install the housing-to-front cover bolts. Tighten the bolts to 23 N.m (200 in. lbs.).
4. Install the radiator upper hose (3) to the thermostat housing (1).
5. Fill the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
6. Connect the negative battery cable.
7. Start and warm the engine. Check for leaks.

1. Clean mating areas of timing chain cover and thermostat housing (1). NOTE: Install thermostat with the bleed valve located at the 12 o'clock position.
2. Install thermostat (2) (spring side down) into recessed machined groove on timing chain cover with bleed valve located at the 12 o'clock position.
3. Position thermostat housing (1) on timing chain cover. CAUTION: Thermostat housing must be tightened evenly and thermostat (2) must be centered into recessed groove in timing chain cover. If not, it may result in a cracked thermostat housing (1), damaged timing chain cover threads or coolant leaks.
4. Install two housing-to-timing chain cover bolts (3). Tighten bolts to 13 N.m (112 in. lbs.) torque.
5. Install lower radiator hose on thermostat housing.
6. Lower vehicle.
7. Fill cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
8. Connect negative battery cable to battery.
9. Start and warm the engine. Check for leaks.

Scheme 67

1. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
2. Remove upper and lower intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-354006-S38508227272010011300000) , and refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-354006-S38508227272010011300000) .
3. Position lower intake manifold upside down on bench and remove the tube retaining bolt (5).
4. Remove heater supply tube (4) from manifold and discard O-ring (2).

Scheme 68

1. Disconnect negative battery cable.
2. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-354006-S38508227272010011300000) .
4. Remove heater hoses from heater tubes.
5. Remove heater tube mounting bolts.
6. Remove heater tubes from water pump housing and remove from vehicle.

1. Disconnect negative battery cable.
2. Drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Remove intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Removal»(ref-354006-S38508227272010011300000) .
4. Remove heater hoses from heater tubes.
5. Remove heater tube mounting bolts.
6. Remove heater tubes from water pump housing and remove from vehicle.

1. Clean heater tube sealing surfaces.
2. Inspect heater tube O-ring (2). Replace as necessary.
3. Lubricate O-ring (2) with a silicone type grease such as Mopar® Dielectric Grease.
4. Install O-ring (2) on heater supply tube (4).
5. Install heater tube (4) on manifold.
6. Install retaining bolts. Tighten bolts to 12 N.m (105 in. lbs.).
7. Install lower and upper intake manifolds. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-354006-S03939495892010011300000) , and refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-354006-S03939495892010011300000) .
8. Refill cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
9. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid levels.

1. Position heater tubes into water pump housing.
2. Install mounting bolts. Tighten bolts to 10 N.m (88 in. lbs.).
3. Install heater hose onto heater tubes.
4. Install intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-354006-S03939495892010011300000) .
5. Connect negative battery cable.
6. Fill cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
7. Start vehicle and check for cooling system leaks.

1. Position heater tubes into water pump housing.
2. Install mounting bolts. Tighten bolts to 10 N.m (88 in. lbs.).
3. Install heater hose onto heater tubes.
4. Install intake manifold. Refer to «Engine/Manifolds/MANIFOLD, Intake - Installation»(ref-354006-S03939495892010011300000) .
5. Connect negative battery cable.
6. Fill cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
7. Start vehicle and check for cooling system leaks.

Scheme 69

1. Remove dust cap by pulling it straight back off of quick connect fitting.
2. Place disconnect 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 70

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.

TRANSMISSION OIL COOLER CLEANING

Note. Always start the cleaning procedure by reverse flushing the system first.

Note. Refer to the Transmission Cooler Cleaner's operating instructions before starting this procedure.

1. With the transmission removed from the vehicle. Use tool 9038-1, trans cooler cleaner adapter kit (TCCAK) (1), to select the proper adapter/fitting for the vehicle you are performing the procedure on.
2. Install the selected adapter/fitting to the transmission oil cooler inlet (2) and outlet (1) lines.
3. Connect the blue hose (inlet) of the 9038 trans cooler cleaner (TCC) to the transmission oil cooler outlet line (1).
4. Connect the red hose (outlet) of the 9038 trans cooler cleaner (TCC) to the transmission oil cooler inlet line (2).
5. Before starting the 9038 trans cooler cleaner (TCC), check the filter screen (2) for any debris. If debris is present, clean the filter screen in a parts washer and dry completely. CAUTION: FILTER SCREEN (2) MUST BE COMPLETELY CLEAN AND DRY BEFORE PROCEEDING. FAILURE TO COMPLY COULD RESULT IN POSSIBLE CONTAMINATION AND DAMAGE TO THE COOLING SYSTEM.
6. Refer to the 9038 transmission cooler cleaner's (TCC) owners manual and quick reference card for detailed operating instructions. NOTE: It is recommended to flush/clean the system in 30 minute intervals.
7. Check the filter screen (2) for any debris. If debris is present after the cleaning procedure is complete, clean the filter screen in a parts washer, dry completely, repeat the reverse flush procedure and repeat the cleaning procedure.
8. Install the transmission to the vehicle. Refer to the specific vehicle's transmission installation procedure.

Scheme 71

The automatic transmission cooler (2) 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, a tapping block (3) for the receiver/drier (4) and mounting provisions for the power steering cooler (5).

The transmission oil cooler/AC condenser is service as an assembly. For removal. Refer to Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Removal and installation. Refer to Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Installation .