Engine Cooling System & Automatic Transmission Cooling System: Other Dodge Durango II

ULTRAVIOLET LIGHT METHOD

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 36

PRESSURE TESTER METHOD

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) to radiator filler neck (1).

Operate tester pump to apply 103.4 kPa (15 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

Scheme 37

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.

ENGINE COOLING SYSTEM OVERHEATING

Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause

1. Prolonged idle
2. Very high ambient temperature
3. Slight tail wind at idle
4. Slow traffic
5. Traffic jams
6. High speed or steep grades

Driving techniques that avoid overheating are

1. Idle with A/C off when temperature gauge is at end of normal range.
2. Increasing engine speed for more air flow is recommended.

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 .

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

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.

COOLANT LEVEL CHECK

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 (5) provides a quick method for determining coolant level without removing radiator pressure cap. With engine not running, open the coolant recovery bottle cap and remove coolant level indicator dipstick to observe coolant level in coolant recovery bottle. The coolant level should be between ADD and FULL marks. If the coolant level is at or below the ADD 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.

Scheme 38

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.

3.7L/4.7L ENGINE

On 4.7L engines, the tensioner (3) 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 24 mm (.94 inches) of indexing stop. Belt is considered new if it has been used 15 minutes or less.

If the above specification cannot be met, check for

1. The wrong belt being installed (incorrect length/width)
2. Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator)
3. A pulley on an engine accessory being loose
4. Misalignment of an engine accessory
5. Belt incorrectly routed.

Note. A used belt should be replaced if tensioner indexing arrow has moved to the minimum tension indicator. Tensioner travel stops at this point.

1. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
2. Remove tensioner assembly from mounting bracket (1). WARNING: BECAUSE OF HIGH SPRING PRESSURE, DO NOT ATTEMPT TO DISASSEMBLE AUTOMATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
3. Remove pulley bolt. Remove pulley from tensioner.

5.7L ENGINE

1. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
2. Remove tensioner and mounting bracket.
3. Remove the tensioner assembly from the mounting bracket.

1. Install pulley and pulley bolt to tensioner. Tighten bolt to 61 N.m (45 ft. lbs.) torque.
2. An indexing slot is located on back of tensioner. Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt to 41 N.m (30 ft. lbs.).
3. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
4. Check belt indexing marks.

1. Install tensioner on to the mounting bracket. Tighten bolt to 41 N.m (30 ft. lbs.).
2. Install tensioner and bracket assembly
3. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).

3.7L ENGINE

The Engine Coolant Temperature (ECT) sensor (3) on the 3.7L engine is installed into a water jacket at front of intake manifold near rear of generator.

1. Partially drain the cooling system. (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
2. Disconnect the electrical connector from the sensor (3).
3. Remove the sensor from the intake manifold.

Scheme 39

4.7L V-8

The Engine Coolant Temperature (ECT) sensor (1) on the 4.7L V-8 engine is located near the front of the intake manifold.

1. Partially drain the cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
2. Disconnect the electrical connector from the ECT sensor (1).
3. Remove the sensor (1) from the intake manifold.

Scheme 40

5.7L V-8

The Engine Coolant Temperature (ECT) sensor (3) on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block.

1. Partially drain the cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
2. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
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.

Scheme 41

1. Apply thread sealant to sensor threads.
2. Install engine coolant sensor into intake manifold. (3). Tighten sensor to 11 N.m (97.3 in. lbs.) torque.
3. Connect the electrical connector.
4. Fill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).

Scheme 42

1. Apply thread sealant to sensor threads.
2. Install ECT sensor (1) to engine.
3. Tighten sensor to 11 N.m (97.3 in. lbs.) torque.
4. Connect electrical connector to sensor (1).
5. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).

Scheme 43

1. Apply thread sealant to sensor threads.
2. Install ECT sensor (3) to engine.
3. Tighten sensor to 11 N.m (97.3 in. lbs.) torque.
4. Connect electrical connector (2) to ECT sensor (3).
5. Fill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).

Scheme 44

If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type.

Scheme 45

1. Disconnect the negative battery cable.
2. Drain the cooling system until the coolant level is below the thermostat (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
3. Air Conditioned vehicles: Remove the support bracket (generator mounting bracket-to-intake manifold) (2) located near the rear of the generator. NOTE: On air conditioning equipped vehicles, the generator must be partially removed.
4. Remove the accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
5. Remove the generator mounting bolts. Do not remove any of the wiring at the generator. If equipped with 4WD, unplug the 4WD indicator lamp wiring harness (located near rear of generator).
6. Remove the generator. Position the generator to gain access for the thermostat gasket removal.
7. Remove the radiator upper hose clamp and upper hose at the thermostat housing.
8. Position the wiring harness (behind thermostat housing) to gain access to the thermostat housing.
9. Remove the thermostat housing mounting bolts, thermostat housing (1), gasket (2) and thermostat (3). Discard old gasket (3).

Scheme 46

Scheme 47

If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.

1. Disconnect negative battery cable at battery.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
3. Raise vehicle on hoist.
4. Remove splash shield.
5. Remove lower radiator hose clamp and lower radiator hose at thermostat housing.
6. Remove thermostat housing mounting bolts, thermostat housing (1) and thermostat (3).

1. Clean the mating areas of the intake manifold and thermostat housing (1).
2. Install the thermostat (4) (spring side down) into the recessed machined groove on the intake manifold.
3. Install the gasket on the intake manifold and over the thermostat.
4. Position the thermostat housing (1) to the intake manifold. Note: The word FRONT stamped on housing. For adequate clearance, this must be placed towards the front of the vehicle. The housing is slightly angled forward after the installation to the intake manifold.
5. Install the housing-to-intake manifold bolts. Tighten the bolts to 23 N.m (200 in. lbs.)
6. Install the radiator upper hose to the thermostat housing.
7. Air Conditioned vehicles; Install the generator. Tighten the bolts to 41 N.m (30 ft. lbs.).
8. Install the support bracket (generator mounting bracket-to-intake manifold).. Tighten the bolts to 54 N.m (40 ft. lbs.).
9. Install the accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
10. Fill the cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
11. Connect battery negative cable.
12. Start and warm the engine. Check for leaks.

Scheme 48

1. Clean mating areas of timing chain cover and thermostat housing.
2. Install thermostat (spring side down) into recessed machined groove on timing chain cover.
3. Position thermostat housing on timing chain cover.
4. Install two housing-to-timing chain cover bolts. Tighten bolts to 13 N.m (112 in. lbs.) torque. CAUTION: Housing must be tightened evenly and thermostat must be centered into recessed groove in timing chain cover. If not, it may result in a cracked housing, damaged timing chain cover threads or coolant leaks.
5. Install lower radiator hose on thermostat housing.
6. Install splash shield.
7. Lower vehicle.
8. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
9. Connect negative battery cable to battery.
10. Start and warm the engine. Check for leaks.

RADIATOR COOLANT FLOW

Use the following procedure to determine if coolant is flowing through cooling system.

1. Idle engine until operating temperature is reached. If upper radiator hose is warm to the touch, thermostat is opening and coolant is flowing to radiator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO FIRST STOP. ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK.
2. Drain a small amount of coolant from radiator until ends of radiator tubes are visible through filler neck. Idle engine at normal operating temperature. If coolant is flowing past exposed tubes, coolant is circulating.

Clean radiator fins. 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.

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 131 kPa (21 psi) and hold pressure at a minimum of 130 kPa (18.8 psi).

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.

RADIATOR CAP

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 138 kPa (20 psi) on gauge. If pressure cap (1) fails to hold pressure of at least 131 kPa (19 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.

Scheme 49

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.

WATER PUMP

A centrifugal water pump (1) circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt that drives the water pump pulley (1).

The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary.

Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley.

Scheme 50

WATER PUMP BYPASS - 4.7L

The 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. The thermostat (4) uses a stub shaft located at the rear of the thermostat to control flow through the bypass gallery.

Scheme 51

A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt.

WATER PUMP BYPASS - 4.7L ENGINE

When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the pill partially covers the bypass hole, reducing the amount of bypass flow. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal temperature operation.

The water pump on 3.7L/4.7L engines is bolted directly to the engine timing chain case cover.

1. Disconnect negative battery cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
3. Remove fan/viscous fan drive assembly from water pump (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ). Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
4. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive.
5. Remove two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector.
6. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle.
7. After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant.
8. Remove accessory drive belt from the water pump pulley (2) (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
9. Remove lower radiator hose clamp and remove lower hose at water pump.
10. Remove seven water pump mounting bolts and one stud bolt. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
11. Remove water pump and gasket. Discard gasket.

1. Disconnect negative battery cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
3. Remove fan/viscous fan drive assembly from water pump (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ). Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
4. If water pump is being replaced, do not unbolt fan blade assembly from thermal viscous fan drive.
5. Remove two fan shroud-to-radiator screws. Disconnect the coolant overflow hose, windshield washer fluid hose and washer pump electrical connector.
6. Remove fan shroud and fan blade/viscous fan drive assembly from vehicle.
7. Remove A/C compressor and generator brace.
8. Remove idler pulleys.
9. Remove belt tensioner assembly (Refer to «TENSIONERS-BELT»(ref-212747-S22817230792006072400000) ).
10. Remove upper and lower radiator hoses.
11. Remove heater hoses.
12. Remove water pump mounting bolts and remove pump.

Clean the gasket mating surface. Use caution not to damage the gasket sealing surface.

3.7/4.7L ENGINE

1. Clean gasket mating surfaces.
2. Using a new gasket, position water pump (1) and install mounting bolts as shown. Tighten the water pump mounting bolts to 24 N.m (18 ft. lbs.) for 3.7L engines. On 4.7L engines, for appropriate bolt tightening specification, refer to «FASTENER IDENTIFICATION»(ref-285315-S01285940972008052100000) .
3. Spin water pump to be sure that pump impeller does not rub against timing chain case/cover.
4. Connect radiator lower hose to water pump.
5. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
6. Position fan shroud and fan blade/viscous fan drive assembly.
7. Install two fan shroud-to-radiator screws.
8. Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud.
9. Install fan blade/viscous fan drive assembly to water pump shaft (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
10. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
11. Connect negative battery cable.
12. Start and warm the engine. Check for leaks.

1. Install water pump and mounting bolts. Tighten mounting bolts to 24 N.m (18 ft. lbs.).
2. Install heater hoses.
3. Install upper and lower radiator hoses.
4. Install belt tensioner assembly (Refer to «TENSIONERS-BELT»(ref-212747-S22817230792006072400000) ).
5. Install idler pulleys.
6. Install A/C compressor and alternator brace. Tighten bolt and nuts to 28 N.m (21 ft. lbs.).
7. Install fan shroud assembly and two fan shroud mounting screws.
8. Install the fan/viscous drive assembly (Refer to «FAN-RADIATOR VISCOUS»(ref-212747-S08435546542006072400000) ).
9. Be sure of at least 25 mm (1.0 inches) between tips of fan blades and fan shroud.
10. Install accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
11. Connect negative battery cable.
12. Fill coolant (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
13. Pressure test coolant system (Refer to «DIAGNOSIS AND TESTING»(ref-212747-S18886768882005122700000) ).

LEAKS

Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit.

VISCOUS DRIVE

If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool.

For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature.

1. Drill a 3.18-mm (1/8-in) diameter hole in the top center of the fan shroud.
2. Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18°-to-105°C (0°-to 220° F). Insert thermometer through the hole in the shroud. Be sure that there is adequate clearance from the fan blades.
3. Connect a tachometer and an engine ignition timing light. The timing light is to be used as a strobe light. This step cannot be used on the diesel engine.
4. Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator. Use tape at the top to secure the plastic and be sure that the air flow is blocked.
5. Be sure that the air conditioner (if equipped) and blower fan is turned off. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.
6. Start the engine and operate at 2400 RPM. Within ten minutes the air temperature (indicated on the dial thermometer) should be up to 88° C (190° F). Fan drive engagement should start to occur at/between: 3.7L Automatic - 93° C - 99°C (200° F - 210° F) 3.7L Manual/4.7L Automatic/5.9L - 85° - 91° C (185° - 195° F) 4.7L Manual - 74° - 79° C (165° - 175° F) Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light also will indicate an increase in the speed of the fan.
7. When viscous drive engagement is verified, remove the plastic sheet. Fan drive disengagement should start to occur at or between

1. 3.7L Automatic - 76°C - 81°C (168° F - 178° F)
2. 3.7L Manual/4.7L Auto - 67°C - 73°C (153° F - 163° F)
3. 4.7L Manual - 56°C - 62°C (133° F - 143° F)
4. 5.7L A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit.

Clean the fan blades using a mild soap and water. Do not use an abrasive to clean the blades.

WITHOUT AIR CONDITIONING

1. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
2. Loosen both bypass hose clamps and position to center of hose. Remove hose from vehicle.

WITH AIR CONDITIONING

If equipped with A/C, the generator and A/C compressor along with their common mounting bracket (2) must be partially removed. Removing generator or A/C compressor from their mounting bracket is not necessary. Also, discharging A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor.

Scheme 52

1. Disconnect battery negative cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
3. Remove upper radiator hose clamp and hose at radiator.
4. Unplug wiring harness from A/C compressor.
5. Remove air cleaner assembly.
6. Remove accessory drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
7. Remove bracket-to-intake manifold bolts.
8. The drive belt idler pulley must be removed to gain access to one of A/C compressor/generator bracket mounting bolts (3). Remove idler pulley bolt and remove idler pulley.
9. Remove oil dipstick tube mounting bolt (3) at side of A/C-generator mounting bracket.
10. Disconnect throttle body cables.
11. Remove heater hose clamp and heater hose from heater hose coolant return tube.
12. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring.
13. Remove six bracket bolts.
14. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position.
15. Loosen and position both hose clamps to center of bypass hose. Remove hose from vehicle.

1. Position bypass hose clamps to center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
5. Start and warm the engine. Check for leaks.

1. Position bypass hose clamps to center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Install generator-A/C mounting bracket assembly to engine. Tighten bolts (number 1 and 2) to 54 N.m (40 ft. lbs.) torque. Tighten bolts (number 3) to 40 N.m (30 ft. lbs.) torque.
5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine.
7. Connect throttle body control cables.
8. Install oil dipstick mounting bolt.
9. Install idler pulley. Tighten bolt to 54 N.m (40 ft. lbs.) torque.
10. Install drive belt (Refer to «BELTS-DRIVE»(ref-212747-S08666401972006072400000) ).
11. Install air cleaner assembly.
12. Install upper radiator hose to radiator.
13. Connect wiring harness to A/C compressor.
14. Connect battery negative cable.
15. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
16. Start and warm the engine. Check for leaks.