Engine Cooling System & Automatic Transmission Cooling System: Removal & Installation Dodge Durango II

INSTALLATION - 3.7L/4.7L/5.7L

Belt tension is not adjustable. Belt adjustment is maintained by an automatic (spring load) belt tensioner.

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. Install new belt. Route the belt around all pulleys except the idler pulley (5). Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler (5) and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all pulleys.
3. With the drive belt installed, inspect the belt wear indicator. On 4.7L Engines only, the gap between the tang and the housing stop (measurement A) must not exceed 24 mm (.94 inches). If the measurement exceeds this specification replace the serpentine accessory drive belt.

REMOVAL

1. Disconnect negative battery cable from battery.
2. Drain coolant from radiator (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
3. Raise vehicle.
4. Remove engine cylinder block drain plug(s) (1) located on the sides of cylinder block above the oil pan rail.
5. Remove power cord from block heater.
6. Loosen screw at center of block heater. Remove heater assembly (1).

Scheme 32

INSTALLATION

1. Thoroughly clean cylinder block core hole and block heater seat.
2. Insert block heater assembly with element loop pointing at twelve o'clock.
3. With block heater fully seated, tighten center screw to 2 N.m (17 in. lbs.) torque.
4. Refill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
5. Start and warm the engine. Check for leaks.

1. Disconnect battery negative cable.
2. Drain cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) )
3. Remove pushpins (1) and the upper condenser/radiator seal (2).
4. Remove air filer housing assembly. (Refer to AIR CLEANER ELEMENT in appropriate ENGINE article).
5. Remove upper radiator hose (1).
6. Remove overflow tube (2).
7. Remove radiator fan shroud (4) from the radiator and position over the radiator fan.
8. Remove the upper radiator support (3).
9. Raise vehicle.
10. Disconnect the power steering cooler lines (2).
11. Disconnect the transmission cooler lines (1).
12. Remove the lower radiator hose (2).
13. Lower vehicle.
14. Remove upper radiator mount.
15. Remove LH and RH radiator side seals.
16. Remove radiator.
17. Remove power steering cooler form the radiator, if necessary.
18. Remove transmission cooler from radiator, if necessary.

The radiator has two isolator pins on bottom of both tanks. These fit into alignment holes in radiator lower support.

1. Install power steering cooler, if removed.
2. Install transmission oil cooler if removed.
3. Install the upper radiator mount
4. Position isolator pins into alignment holes in radiator lower support.
5. Install upper radiator support. Tighten bolts to 23 N.m (200 in. lbs.)
6. Install LH and RH radiator side seals.
7. Install upper radiator hose.
8. Install overflow tube.
9. Install radiator shroud.
10. Raise vehicle.
11. Install power steering cooler lines.
12. Install transmission cooler lines.
13. Install lower radiator hose.
14. Lower vehicle.
15. Install air filter housing assembly (Refer to AIR CLEANER ELEMENT in appropriate ENGINE article).
16. Fill radiator (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
17. Connect battery negative cable.
18. Start and warm the engine. Check for leaks.

1. Partially drain the cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
2. Remove the upper radiator hose.
3. Remove the air filter housing assembly (Refer to AIR CLEANER ELEMENT in appropriate ENGINE article).
4. Using Tool 6958 and adapter pins 8346 (1), remove fan/viscous fan drive assembly from water pump. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
5. Position the fan/fan drive assembly in the radiator shroud.
6. Remove the two shroud mounting screws.
7. Remove the radiator shroud and fan drive assembly.
8. After removing fan blade/viscous fan drive assembly, do not place viscous fan drive in horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant.
9. Remove four bolts securing fan blade assembly to viscous fan drive.

1. Install fan blade assembly to viscous fan drive. Tighten bolts to 23 N.m (17 ft. lbs.) torque.
2. Position fan blade/viscous fan drive assembly into the radiator shroud.
3. Install the radiator shroud and fan drive assemble into the vehicle.
4. Install fan shroud retaining screws. Tighten screws to 6 N.M (50 lbs. in.)
5. Install fan blade/viscous fan drive assembly to water pump shaft.
6. Install the upper radiator hose.
7. Fill cooling system (Refer to «REFILLING COOLING SYSTEM»(ref-212747-S15342466592005122700000) ).
8. Connect battery negative cable.

1. Remove pushpins (1) and the upper condensor/radiator seal (2).
2. Remove upper radiator support.
3. Remove upper transmission cooler mounting bolt.
4. Raise vehicle.
5. Disconnect the transmission cooler lines (1).
6. Remove lower transmission cooler mounting bolts.
7. Remove transmission cooler from vehicle.

Scheme 33

1. Position transmission cooler in vehicle.
2. Install lower transmission cooler mounting bolt. Tighten to 10 N.NM (90 in. lbs.)
3. Connect transmission cooler lines.
4. Lower vehicle.
5. Install upper transmission cooler mounting bolt. Tighten bolt to 10 N.m (90 in. lbs.).
6. Install upper condenser/radiator seal.
7. Check transmission fluid level (Refer to «CHECKING FLUID LEVEL»(ref-170067-S17426121062005010300000) ).