Engine Cooling System: Removal & Installation Dodge Challenger III

INSTALLATION

1. Position coolant recovery container (3).
2. Install mounting nuts (2). Tighten to 10 N.m (89 in. lbs.).
3. Install coolant recovery tube (1).
4. Fill cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
5. Install coolant recovery container pressure cap (4).

Scheme 22

All cooling systems are equipped with a pressure cap on the radiator. This cap releases pressure at some point within a range of 110-138 kPa (16-20 psi). The pressure relief point (in pounds) is engraved on top of the cap (3).

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 (4). This valve opens when system pressure reaches the release range of 110-138 kPa (16-20 psi).

A rubber gasket (2) seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure.

1. Position fan motor on radiator fan shroud.
2. Install mounting bolts. Tighten to 10 N.m (89 in. lbs.).
3. Position fan blade on motor and install retaining nut. Tighten nut to 25 N.m (221 in. lbs.).
4. Position radiator cooling fan assembly (1) in vehicle.
5. Install cooling fan mounting bolts. Tighten to 6 N.m (50 in. lbs.)
6. Connect cooling fan electrical connector (2).
7. Install upper radiator hose (3).
8. Install the air filter housing. Refer to «Engine/Air Intake System/BODY, Air Cleaner - Installation»(ref-354006-S05303918372010011300000) .
9. Fill the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
10. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for correct fluid levels.

Scheme 23

The 3.5L engine block heater (1) is mounted in the cylinder block (2), near the right rear corner. The engine block heater (1) is a dry cylinder type design and is powered by 110 volt AC.

Scheme 24

The 5.7L and 6.1L engine block heater (1) is mounted in the cylinder block, near the left rear corner. The engine block heater (1) is a dry cylinder type design and is powered by 110 volt AC.

1. Position the radiator into engine compartment. Seat the radiator assembly lower rubber isolators into the mounting holes in radiator lower support.
2. Install the radiator mounting bracket (1) and bolts (2). Tighten to 12 N.m (106 in. lbs.).
3. Position the condenser on radiator and install upper mounting bolts. Tighten bolts to 6 N.m (50 in. lbs.).
4. Raise the vehicle. 1 - LOWER RADIATOR HOSE 2 - RADIATOR FAN ASSEMBLY
5. Install the lower condenser mounting bolts. Tighten bolts to 10 N.m (88 in. lbs.)
6. Install the lower radiator hose (1) and clamp.
7. Lower the vehicle. 1 - UPPER RADIATOR CLOSURE PANELS 2 - UPPER RADIATOR HOSE 3 - RADIATOR FAN ELECTRICAL CONNECTOR 4 - RADIATOR FAN ASSEMBLY
8. Install the radiator fan. See «Cooling/Engine/FAN, Cooling - Installation»(ref-353989-S05750560782010011300000) .
9. Install the upper radiator upper hose. Align hose so it does not interfere with the accessory drive belt or engine. Position hose clamp so it will not interfere with the hood.
10. Install the upper radiator closure panels.
11. Connect the negative cable.
12. Fill the cooling system with coolant. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
13. Operate the engine until it reaches normal operating temperature. Check the cooling system and automatic transmission for the correct fluid levels.

Scheme 25

1. Disconnect negative battery cable.
2. Partially drain cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. With the engine cold, disconnect coolant sensor electrical connector.
4. Remove sensor (2).

Scheme 26

1. Partially drain the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
2. Remove the accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353989-S00873162722010011300000) .
3. Carefully unbolt the air conditioning compressor from the front of engine. Do not disconnect any A/C hoses from the compressor. Temporarily support the compressor to gain access to the ECT sensor (3).
4. Disconnect the electrical connector (2) from the sensor (3).
5. Remove the sensor (3) from cylinder block cylinder block.

Scheme 27

1. Partially drain the cooling system. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
2. Remove accessory drive belt. See «Cooling/Accessory Drive/BELT, Serpentine - Removal»(ref-353989-S00873162722010011300000) .
3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor (3).
4. Disconnect electrical connector (2) from sensor (3).
5. Remove sensor (3) from cylinder block.

REMOVAL

1. Remove upper radiator closure panels
2. Using Release Tool 8875A, remove transmission cooler lines from transmission cooler. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
3. Raise vehicle on hoist.
4. Remove front transmission cooler lines from the thermal bypass valve block.
5. Remove rear transmission cooler lines from the thermal bypass valve block
6. Remove the transmission cooler lines from the transmission.

1. Install rear transmission cooler lines at transmission. Tighten fittings to 20 N.m (18 ft. lbs.).
2. Install rear transmission cooler lines to thermal bypass valve. Tighten fittings to 20 N.m (18 ft. lbs.).
3. Install front transmission cooler lines to thermal bypass valve. Tighten fittings to 20 N.m (18 ft. lbs.).
4. Install front transmission cooler lines into transmission cooler. See «Cooling - Standard Procedure»(ref-353989-S26378580252010011300000) .
5. Lower vehicle.
6. Check transmission fluid level. Refer to «Transmission and Transfer Case/Automatic - 42RLE/FLUID and FILTER - Standard Procedure»(ref-354007-S41533514502010011300000) , or refer to «Transmission and Transfer Case/Automatic - NAG1/FLUID and FILTER - Standard Procedure»(ref-354008-S12164514142010011300000) .

Scheme 28

The transmission thermal bypass valve is mounted on LH side of the engine at the A/C compressor.

1. Raise and support vehicle.
2. Remove front transmission cooler lines from the thermal bypass valve block (2).
3. Remove rear transmission cooler lines from the thermal bypass valve block (2).
4. Remove thermal bypass valve block (2).

1. Position thermal bypass valve. Install mounting bolt. Tighten mounting bolt to: 3.5L engine to 26 N.m (19 ft.lbs.) and 5.7L/6.1L engine to 50 N.m (37 ft. lbs.).
2. Install rear transmission cooler lines to thermal bypass valve. Tighten fittings to 20 N.m (18 ft. lbs.).
3. Install front transmission cooler lines to thermal bypass valve. Tighten fittings to 20 N.m (18 ft. lbs.).