Engine Cooling System: Removal & Installation Dodge Dart PF

REMOVAL

1. Remove the serpentine belt (5).
2. Remove the idler pulley (3) center bolt.
3. Remove the idler pulley.

INSTALLATION

1. Position the idler pulley (3) into position.
2. Install the center bolt. Tighten the bolt to 28 N.m (21 ft. lbs).
3. Install the accessory drive belt (5). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-646235-S37622997972014072800000) .

Scheme 3

Note. View typical

1. Disconnect the negative battery cable.
2. Drain the coolant level below the coolant recovery bottle. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
3. Remove the return hose (1).
4. Remove the lower supply hose (4).
5. Remove the mounting screw (3).
6. Remove the coolant recovery bottle from the strut tower.

Note. View typical

1. Position the coolant bottle into the mounts.
2. Install the mounting screw (3). Tighten to 8 N.m (70 in. lbs.).
3. Install the lower supply hose (4).
4. Install the return hose (1).
5. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .

Scheme 4

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

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

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

Scheme 5

Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester (special tool #7700, Tester, Cooling System) or an equivalent.

Using the cooling system tester, bring the pressure up to the pressure prescribed on cap. If the pressure cap fails to hold pressure, replace the cap. Refer to the following CAUTION .

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

Scheme 6

Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap.

Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator.

Note. The cooling fan must be removed from the top of the vehicle.

Scheme 7

1. Disconnect the negative battery cable.
2. Remove the engine cover and the air intake assembly. Refer to «RESONATOR, AIR CLEANER, REMOVAL, 2.0L»(ref-646216-S00754484562014072800000) or «RESONATOR, AIR CLEANER, REMOVAL, 2.4L»(ref-646217-S01497312852014072800000) .
3. Disconnect the cooling fan resistor (3) harness connector and retainer push pin at the cooling fan.
4. Remove the cooling fan mounting bolts (1).
5. Lift the fan slightly upward.
6. Tilt the cooling fan down on the right side to allow for the left upper mounting tab to clear the upper radiator hose.
7. Remove the fan assembly from the vehicle by lifting the left side up and out of the vehicle.

1. Guide the cooling fan into position onto the radiator tabs through the top of the vehicle by tilting the right side in first to allow for the left side to clear the upper radiator hose.
2. Once into position, insert the lower tabs into the retainers (2).
3. Install the mounting bolts (1). Tighten mounting bolts to 8 N.m (70 in.lbs.).
4. Install the wire harness connectors (3) to the cooling fan.
5. Install the engine cover and air intake assembly. Refer to «RESONATOR, AIR CLEANER, INSTALLATION, 2.0L»(ref-646216-S21595726612014072800000) or «RESONATOR, AIR CLEANER, INSTALLATION, 2.4L»(ref-646217-S37132917522014072800000) .

Scheme 8

An optional engine block heater (2) is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures.

The heater is mounted in a freeze plug hole in the engine cylinder block with the heating element that is submersed into coolant. The heater is located on the rearward side of the engine block and can be accessed from the bottom of the vehicle.

Scheme 9

An optional engine block heater (3) is available with all models. The heater is equipped with a power cord (1). The cord is attached to the engine with a tie-strap. The heater warms the engine through conduction providing easier engine starting and faster warm-up in low temperatures.

The heater is mounted in a dry socket hole cast into the left side of the engine cylinder block. It can be accessed from the top of the vehicle. The heater is held in place by a tension tab (2).

Scheme 10

1. Disconnect and isolate the negative battery cable.
2. Raise and support vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-646211-S00664313032014072800000) .
3. If equipped, remove the belly pan.
4. Drain out enough coolant to bring the level below the pump.
5. Remove the engine cover, if equipped.
6. Remove the air cleaner assembly. Refer to «AIR CLEANER, REMOVAL, 2.0L»(ref-646216-S32691632802014072800000) or «AIR CLEANER, REMOVAL, 2.4L»(ref-646217-S18981223602014072800000) .
7. Disconnect the after-run pump electrical connector (4).
8. Using (special tool #10288, Pliers, Hose Clamp) release and reposition the hose clamps (6 and 7) to allow for hose removal.
9. Disconnect the hoses (2) from the pump.
10. Remove the two bracket bolts.
11. Remove the pump.

1. Position the pump and install the two bracket bolts. Tighten the bolts to 10 N.m (89 in. lbs.).
2. Attach the inlet (6) and outlet (7) hoses to the pump.
3. Using (special tool #10288, Pliers, Hose Clamp) reposition the hose clamps to the proper position and activate the clamps to tension.
4. Connect the pump electrical connector (4).
5. Install the air cleaner assembly. Refer to «AIR CLEANER, INSTALLATION, 2.0L»(ref-646216-S41193092632014072800000) or «AIR CLEANER, INSTALLATION, 2.4L»(ref-646217-S03307573772014072800000) .
6. Install the engine cover.
7. Top off the coolant.
8. Start the engine and check for leaks.

Scheme 11

Scheme 12

1. Disconnect the battery negative cable.
2. Remove the engine cover and the air intake assembly (1). Refer to «RESONATOR, AIR CLEANER, REMOVAL, 2.0L»(ref-646216-S00754484562014072800000) or «RESONATOR, AIR CLEANER, REMOVAL, 2.4L»(ref-646217-S01497312852014072800000) .
3. Evacuate the A/C system. Refer to «CONDENSER, A/C, REMOVAL»(ref-646220-S02891918702014072800000) .
4. Raise and support the vehicle.
5. Remove the belly pan. Refer to «BELLY PAN, REMOVAL»(ref-646214-S24731623582014072800000) .
6. Drain the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
7. Disconnect the cooling fan resistor (3).
8. Remove the radiator fan assembly. Refer to «FAN, COOLING, REMOVAL»(ref-646235-S02837375212014072800000) .
9. Turbocharged only: Remove the front bumper fascia. Refer to «FASCIA, FRONT, REMOVAL»(ref-646214-S35831020322014072800000) .
10. Turbocharged only: Remove the charge air cooler. Refer to «COOLER AND HOSES, CHARGE AIR, REMOVAL»(ref-646215-S30017359832014072800000) .
11. Remove the lower radiator hose.
12. Separate the air-conditioning liquid line near the right upper mount (2). NOTE: It is necessary to separate the liquid line to allow the radiator upper mount to be removed from the right side.
13. Remove and discard the O-ring.
14. Remove the isolators screws from the upper core support (1) from the left and right mounting locators.
15. Remove the radiator from the vehicle. NOTE: The radiator and cooling fan should be removed from the top by slightly rotating the components down on the right while tilting the component rearward. The left end of the component should lead out of the vehicle. .
16. Remove the A/C condenser from the cooling module (3) from the radiator (1). Refer to «CONDENSER, A/C, REMOVAL»(ref-646220-S02891918702014072800000) .

Scheme 13

1. Install the A/C condenser. Tighten the condenser retaining screws (2) to 8 N.m (70 in. lbs.). Refer to «CONDENSER, A/C, INSTALLATION»(ref-646220-S40205564972014072800000) .
2. Position the radiator into the lower mounting isolators on the radiator lower core support.
3. Install the retainers over the radiator isolators. Insert the retainer screws (1). Tighten the screws to 50 N.m (37 ft. lbs.).
4. Install the radiator fan into the radiator lower retainers (2).
5. Install the upper radiator cooling fan bolts (1). Tighten the radiator fan retaining bolts to 11 N.m (97 in. lbs.).
6. Install the new seals onto the A/C fittings. Install the bolt (2). Tighten the bolt to
7. Recharge the A/C system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-646220-S33335783492014072800000) .
8. Install the lower radiator hose. Tighten clamp.
9. Install the upper radiator hose. Tighten clamp.
10. Lower vehicle.
11. Install the upper radiator hose
12. Connect the radiator fan connector (3). CAUTION: The FIAT engines use a OAT coolant. OAT coolant CAN NOT be mixed with and other kinds of coolant. Heavy corrosion or damage may occur to the cooling system or engine, unless the proper coolant has been used.
13. Fill the cooling system with OAT coolant. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
14. Install the engine cover and air intake assembly.
15. Connect the battery negative cable.

Scheme 14

Scheme 15

1. Drain the cooling system.
2. Disconnect the positive (1) and negative (2) battery cable.
3. Remove the nut (3) for the battery hold down clamp and remove battery.
4. Remove the engine cover.
5. Remove the air intake assembly.
6. Disconnect the engine coolant temperature sensor harness connector.
7. Remove the temperature sensor (4) from the thermostat housing.

1. Install the engine coolant temperature sensor (4) into the thermostat housing.
2. Connect the wire harness connector.
3. Install the battery (4) and the hold down clamp. Tighten the nut to 55 N.m (40 ft. lbs.).
4. Install the air intake assembly.
5. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-646235-S03842909342014072800000) .
6. Connect the positive and negative battery cable.

1. Position the transmission oil cooler over the cooler retainers.
2. Push the cooler assembly rearward to seat the cooler retainers (1) over the expanders.
3. Visually inspect to be sure the expanders have fully engaged the cooler retainers.
4. Insert the cooler lines into the cooler ports (1). Once an audible click is heard, slightly pull on the lines to be sure they have seated fully.
5. Slide the plastic covers over the fittings. NOTE: If the plastic caps will not fit over the quick connects, inspect for a line that is not fully seated or a spring clip loose.
6. Tighten the bracket bolt to 9 N.m (80 in. lbs.).
7. Install the belly pan and front closeout panel. Refer to «BELLY PAN, INSTALLATION»(ref-646214-S07994234782014072800000) .
8. Lower the vehicle.
9. Check transmission fluid level, add as necessary.