Engine Cooling System: Removal & Installation Dodge Pickup R1500

REMOVAL

1. Remove recovery hose from radiator.
2. Remove the coolant container to fan shroud mounting bolt.
3. Tilt the container backward towards the engine to disengage the mounting pin locking features, and lift the container away from the fan shroud see scheme 1

INSTALLATION

1. Align the coolant container mounting pins into the slots on the fan shroud, and push the container onto the fan shroud.
2. Secure the container to the fan shroud with the bolt. Tighten to 8.5 N.m (75 in. lbs). NOTE: Ensure that the locking feature on the mounting pins has engaged.
3. Connect the recovery hose to the radiator see scheme 1

1. Drain enough coolant from the system so that the degas container is empty. Refer to «COOLING»(ref-189654-S13811322982005091200000).
2. Loosen the clamps securing the supply and return hoses to the container, and remove the hoses.
3. Remove the coolant container to fan shroud mounting bolts.
4. Tilt the container back towards the engine to disengage the mounting pin locking features, and lift the container away from the fan shroud see scheme 2

1. Align the mounting pins into the slots on the fan shroud, and push the container into the fan shroud.
2. Secure the coolant container to the fan shroud with bolts. Tighten to 8.5 N-m (75 in. lbs). NOTE: Ensure the locking feature on the mounting pins has engaged.
3. Connect the supply and return hoses to the container. and ensure that the hose clamps are positioned properly.
4. Refill the cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000) .

Scheme 61

Scheme 62

1. Disconnect negative battery cable from battery.
2. Remove coolant reserve/overflow container from fan shroud and lay aside. DO NOT disconnect the hoses or drain coolant from the container.
3. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft (Scheme 61) Remove the fan blade/viscous fan drive assembly from the water pump by turning the mounting nut counterclockwise as viewed from the front. Threads on the viscous fan drive are RIGHT-HAND. A 36 MM Fan Wrench should be used to prevent pulley from rotating (Scheme 62)
4. DO NOT attempt to remove the fan/viscous fan drive assembly from the vehicle at this time.
5. DO NOT unbolt the fan blade assembly (Scheme 61) from viscous fan drive at this time.
6. Remove the fan shroud-to-radiator mounting bolts.
7. Pull the lower shroud mounts out of the radiator tank clips.
8. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from vehicle.
9. After removing the fan blade/viscous fan drive assembly, DO NOT place the viscous fan drive in a horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant. CAUTION: Do not remove water pump pulley-to-water pump bolts. This pulley is under spring tension.
10. Remove four bolts securing fan blade assembly to viscous fan drive (Scheme 61)

1. Install fan blade assembly to the viscous fan drive. Tighten the bolts (Scheme 61) to 24 N.m (18 ft. lbs.) torque.
2. Position the fan shroud and the fan blade/viscous fan drive assembly to the vehicle as a complete unit.
3. Install the fan shroud.
4. Install the fan blade/viscous fan drive assembly to the water pump shaft (Scheme 61)
5. Install the coolant reserve/overflow container to the fan shroud.
6. Connect the negative battery cable.

Note. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 RPM and hold for approximately two minutes. This will ensure proper fluid distribution within the drive.

Scheme 63

1. Disconnect the battery negative cables.
2. Remove the fan shroud lower half by unsnapping the fastening tabs. CAUTION: Do not remove the fan pulley bolts. This pulley is under spring tension.
3. Disconnect electrical connector.
4. The electronically controlled viscous fan drive/fan blade assembly is attached (threaded) to the fan hub shaft (Scheme 63) Remove the fan blade/fan drive assembly from fan pulley by turning the mounting nut counterclockwise (as viewed from front). Threads on the viscous fan drive are RIGHT-HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between the fan pulley bolts to prevent pulley from rotating.
5. Remove the fan shroud and the fan blade/viscous drive as an assembly from vehicle from under the vehicle.
6. Remove fan blade-to-viscous fan drive mounting bolts.
7. Inspect the fan for cracks, loose or bent fan blades.

1. Install fan blade assembly to electrically controlled viscous fan drive. Tighten mounting bolts to 23 N.m (17 ft. lbs.) torque.
2. Position the fan blade/viscous fan drive to the vehicle as an assembly.
3. Install viscous fan drive assembly on fan hub shaft (Scheme 63) Tighten mounting nut to 33 N.m (24 ft. lbs.) torque.
4. Connect electrical connector.
5. Install the lower fan shroud into position, and verify the locking tabs have seated.
6. Connect the battery negative cables.

Note. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 RPM and hold for approximately two minutes. This will ensure proper fluid distribution within the drive.

1. Clean and inspect the block heater hole.
2. Install the new O-ring seal(s) to heater.
3. Insert the block heater into cylinder block and position the element properly.
4. With the heater fully seated, tighten center screw to 2 N.m (17 in. lbs.).
5. Fill the cooling system with the recommended coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
6. Start and warm the engine.
7. Check the block heater for leaks.

1. Clean and inspect the threads in the cylinder block.
2. Coat heater element threads with Mopar® Thread Sealer with Teflon.
3. Screw block heater into cylinder block and tighten to 43 N.m (32 ft. lbs.).
4. Connect block heater cord and tighten retaining cap.
5. Fill cooling system with recommended coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000)
6. Start and warm the engine.
7. Check block heater for leaks.

Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.

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

Factory installed thermostat housings on 5.9L engine is installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up.

Scheme 64

Scheme 65

Scheme 66

Scheme 67

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 GAS ENGINES»(ref-214291-S35457735152006010600000) ).
3. Air Conditioned vehicles: Remove the support bracket (generator mounting bracket-to-intake manifold) located near the rear of the generator (Scheme 67) NOTE: On air conditioning equipped vehicles, the generator must be partially removed.
4. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-214292) ) (Scheme 68)
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. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of the constant tension clamps (Scheme 69) If replacement is necessary, use only an original equipment clamp with a matching number, letter and width.
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, gasket and thermostat see scheme 21 Discard old gasket.

Scheme 68

Scheme 69

1. Clean the mating areas of the intake manifold and thermostat housing.
2. Install the thermostat (spring side down) into the recessed machined groove on the intake manifold see scheme 21
3. Install the gasket on the intake manifold and over the thermostat see scheme 21
4. Position the thermostat housing to the intake manifold. NOTE: The word FRONT stamped on housing (Scheme 70) 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. 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 wrong direction. (Scheme 71) for the correct 5.9L engine belt routing. The correct belt with correct length must be used.
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). (Scheme 67) Tighten the bolts to 54 N.m (40 ft. lbs.).
9. Install the accessory drive belt (Scheme 68) (Refer to «ACCESSORY DRIVE»(ref-214292) ).
10. Fill the cooling system (Refer to «REFILLING COOLING SYSTEM - ALL GAS ENGINES»(ref-214291-S00568768602006010600000) ).
11. Connect battery negative cable.
12. Start and warm the engine. Check for leaks.

Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.

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

Factory installed thermostat housings on 5.9L engine is installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up.

Scheme 70

Scheme 71

Scheme 72

1. Disconnect the negative battery cable.
2. Drain the cooling system until the coolant level is below the thermostat. Refer to «COOLING»(ref-189654-S13811322982005091200000).
3. Air Conditioned vehicles: Remove the support bracket (generator mounting bracket-to-intake manifold) located near the rear of the generator (Scheme 73) NOTE: On air conditioning equipped vehicles, the generator must be partially removed.
4. Remove the accessory drive belt (Scheme 74) Refer to «DRIVE BELTS - 5.9L»(ref-189655-S27970610772005091200000).
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. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of the constant tension clamps see scheme 27 If replacement is necessary, use only an original equipment clamp with a matching number, letter and width.
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, gasket and thermostat see scheme 28 Discard old gasket.

Scheme 73

Scheme 74

1. Clean the mating areas of the intake manifold and thermostat housing.
2. Install the thermostat (spring side down) into the recessed machined groove on the intake manifold see scheme 28
3. Install the gasket on the intake manifold and over the thermostat see scheme 28
4. Position the thermostat housing to the intake manifold. Note: The word FRONT stamped on housing see scheme 29 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. 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 wrong direction. (Scheme 75)for the correct 5.9L engine belt routing. The correct belt with correct length must be used.
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). (Scheme 73) Tighten the bolts to 54 N.m (40 ft. lbs.).
9. Install the accessory drive belt. Refer to «DRIVE BELTS - 5.9L»(ref-189655-S27970610772005091200000).
10. Fill the cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
11. Connect battery negative cable.
12. Start and warm the engine. Check for leaks.

Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.

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

1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
3. Raise and support the vehicle.
4. Remove the splash shield.
5. Remove the lower radiator hose clamp and the lower radiator hose at the thermostat housing.
6. Remove the thermostat housing mounting bolts, thermostat housing and thermostat (Scheme 77)

1. Clean the mating areas of the timing chain cover and the thermostat housing.
2. Install the thermostat (spring side down) into the recessed machined groove on the timing chain cover (Scheme 77)
3. Position the thermostat housing on the timing chain cover.
4. Install the housing-to-timing chain cover bolts. Tighten the bolts to 13 N.m (112 in. lbs.). CAUTION: The housing must be tightened evenly, and the thermostat must be centered into the recessed groove in the timing chain cover. If not, it may result in a cracked housing, damaged timing chain cover threads or coolant leaks.
5. Install the lower radiator hose on the thermostat housing.
6. Install the splash shield.
7. Lower the vehicle.
8. Fill the cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
9. Connect negative battery cable.
10. Start and warm the engine. Check for leaks.

Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.

1. Disconnect the battery negative cables.
2. Drain cooling system until coolant level is below thermostat. Refer to «COOLING»(ref-189654-S13811322982005091200000). WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special Clamp Tool (number 6094). Snap-On Clamp Tool (Number HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter.
3. Remove radiator hose clamp and hose from thermostat housing.
4. Remove the three (3) water outlet-to-cylinder head bolts, and remove the water outlet connector see scheme 34
5. Clean the mating surfaces of the water outlet connector, and clean the thermostat seat groove at the top of the thermostat housing see scheme 34

1. Inspect thermostat seal for cuts or nicks. Replace if damaged.
2. Install the thermostat into the groove in the top of the cylinder head see scheme 34
3. Install the thermostat housing and bolts. Tighten the bolts to 10 N.m (88 in. lbs.) torque.
4. Install the radiator upper hose and clamp.
5. Fill the cooling system with coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000).
6. Connect the battery negative cables.
7. Start the engine and check for coolant leaks. Run engine to check for proper thermostat operation.

Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.

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

A rubber lip-type seal with a metal shoulder is pressed into the intake manifold beneath the thermostat see scheme 36

Scheme 75

Scheme 76

1. Disconnect negative battery cable at battery.
2. Drain cooling system until coolant level is below thermostat (Refer to «STANDARD PROCEDURE»(ref-189654-S22265685922005091200000) ).
3. Remove the two support rod mounting bolts and remove support rod (intake manifold-to-generator mount) see scheme 37 WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (number 6094). snap-on clamp tool (number hpc-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter.
4. Remove upper radiator hose clamp. Remove upper radiator hose at thermostat housing.
5. Disconnect the wiring connectors at both of the sensors located on thermostat housing.
6. Remove six thermostat housing mounting bolts, thermostat housing and thermostat.

Scheme 77

1. Clean mating areas of intake manifold and thermostat housing.
2. Check the condition (for tears or cracks) of the rubber thermostat seal located in the intake manifold see scheme 38 The thermostat should fit snugly into the rubber seal.
3. If seal replacement is necessary, coat the outer (metal) portion of the seal with Mopar® Gasket Maker. Install the seal into the manifold using Special Seal Tool number C-3995-A with handle tool number C-4171.
4. Install thermostat into recessed machined groove on intake manifold see scheme 38
5. Install thermostat housing see scheme 38
6. Install housing-to-intake manifold bolts. Tighten bolts to 25 N.m (220 in. lbs.) torque. CAUTION: Housing bolts should be tightened evenly to prevent damage to housing and to prevent leaks.
7. Connect the wiring to both sensors.
8. Install the upper radiator hose and hose clamp to thermostat housing.
9. Install support rod.
10. Fill cooling system (Refer to «STANDARD PROCEDURE»(ref-189654-S22265685922005091200000) ).
11. Connect negative battery cable to battery.
12. Start and warm engine. Check for leaks.

1. Disconnect battery negative cables. WARNING: DO NOT remove the cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from the coolant can occur.
2. Drain the cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000). WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter and the correct width
3. Remove the hose clamps and hoses from radiator.
4. Remove the coolant reserve/overflow tank hose from the radiator filler neck.
5. Remove the coolant reserve/overflow tank (5.9L) or the coolant degas container (3.7L/4.7L) from the fan shroud (pull straight up). The tank slips into slots on the fan shroud.
6. Unclip the power steering hoses from the fan shroud.
7. Disconnect the electrical connectors at the windshield washer reservoir tank, and remove the tank.
8. Remove the fan shroud mounting bolts, and pull up and out of the radiator tank clips (Scheme 78) Position shroud rearward over the fan blades towards engine.
9. Disconnect the transmission cooler lines from the transmission cooler, then plug the transmission lines and cooler to prevent leakage.
10. Disconnect the power steering lines from the power steering cooler, then plug the power steering lines and cooler to prevent leakage.
11. Remove the two radiator upper mounting bolts (Scheme 79)
12. Lift the radiator straight up and out of the engine compartment. Take care not to damage cooling fins or tubes on the radiator and oil coolers when removing.

Note. The radiator is equipped with one alignment dowel on the bottom of the outlet tank and one retaining bracket on the front side of the inlet tank. Both features have rubber insulators attached to them that must be present. The alignment dowel fits into a hole at the bottom of the front end sheet metal vertical support post, and the support bracket rests on top of the lower radiator closure tube.

1. Position the fan shroud over the fan blades rearward towards engine.
2. Install the rubber insulators to the lower radiator mounting features (alignment dowel and support bracket at the lower part of the radiator).
3. Lower the radiator into position while guiding the alignment dowel into the vertical post bracket. Position and seat the lower radiator support bracket onto the lower radiator closure tube.
4. Install the upper radiator mounting bolts. Tighten bolts to 8.5 N.m (75 in. lbs.).
5. Connect the lower radiator hose, and install the clamp in the proper position.
6. Connect the power steering hoses to the power steering oil cooler, and install the clamps.
7. Connect the transmission oil cooler lines to the transmission oil cooler, and install the secondary latches.
8. Position the fan shroud into the mounting clips on the radiator tanks, and secure with bolts. Tighten the bolts to 8.5 N.m (75 in. lbs.).
9. Secure the power steering hoses into the clip on the lower fan shroud.
10. Install the windshield washer reservoir tank, and connect the hose and electrical connector.
11. Install coolant reserve/overflow container hose(s) to radiator filler neck, and secure properly with clamps.
12. Install coolant reserve/overflow container or degas container to fan shroud, and tighten the bolts to 8.5 N.m (75 in. lbs.).
13. Connect upper radiator hose and install clamp.
14. Install battery negative cable.
15. Fill cooling system with coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
16. Operate the engine until it reaches normal operating temperature. Check cooling system fluid levels.

1. Install rubber insulators to alignment dowels at lower part of radiator.
2. Lower the radiator into position while guiding the two alignment dowels into lower radiator support. Different alignment holes are provided in the lower radiator support for each engine application.
3. Install two upper radiator mounting bolts. Tighten bolts to 11 N.m (95 in. lbs.) torque.
4. Connect both radiator hoses and install hose clamps.
5. Connect transmission cooler lines to radiator tank. Inspect quick-connect fittings for debris and install until an audible "click" is heard. Pull apart to verify connection.
6. Position power steering cooler on the radiator, and tighten nuts to 8.5 N.m (75 in. lbs.)
7. Attach electronic viscous fan wiring to upper shroud, and install lower shroud.
8. Position coolant recover tank hose, washer bottle hose and the positive battery cable into the clips located on the top of the radiator.
9. Install air box and turbocharger inlet hose. Tighten clamps to 4 N.m (35 in. lbs.).
10. Position heater controls to full heat position.
11. Fill cooling system with coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
12. Operate engine until it reaches normal temperature. Check cooling system and automatic transmission (if equipped) fluid levels.

The water pump on all models can be removed without discharging the air conditioning system (if equipped).

The water pump on all gas powered engines is bolted directly to the engine timing chain case/cover.

On the 5.9L gas powered engine, a gasket is used as a seal between the water pump and timing chain case/cover.

If water pump is replaced because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal viscous fan drive. Refer to FAN DRIVE VISCOUS CLUTCH .

Scheme 78

Scheme 79

Scheme 80

1. Disconnect the negative cable.
2. Drain cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
3. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
4. Remove the radiator fan. Refer to «RADIATOR FAN»(ref-189656-S27247075722005091200000).
5. Remove accessory drive belt (Scheme 84) Refer to «DRIVE BELTS - 5.9L»(ref-189655-S27970610772005091200000).
6. Remove the lower radiator hose and heater hose from the water pump.
7. Loosen the heater hose coolant return tube mounting bolt see scheme 52, and remove the tube from the water pump. Discard the old tube O-ring.
8. Remove the water pump mounting bolts see scheme 53
9. Loosen the clamp at the water pump end of bypass hose see scheme 52 Slip the bypass hose from the water pump while removing pump from vehicle. Do not remove the clamp from the bypass hose.
10. Discard the old gasket.

1. Clean the gasket mating surfaces.
2. Using a new gasket, install the water pump to the engine as follows: Guide the water pump tube into the bypass hose as the pump is being installed. Install the water pump bolts see scheme 53 Tighten the water pump mounting bolts to 40 N.m (30 ft. lbs.) torque.
3. Position the bypass hose clamp to the bypass hose.
4. Spin the water pump to be sure that the pump impeller does not rub against the timing chain case/cover.
5. Install a new o-ring to the heater hose coolant return tube see scheme 52 Coat the new o-ring with antifreeze before installation.
6. Install the coolant return tube and its mounting bolt to the engine see scheme 52 Be sure the slot in the tube bracket is bottomed to mounting bolt. This will properly position return tube.
7. Connect the radiator lower hose to the water pump.
8. Connect the heater hose and hose clamp to the coolant return tube.
9. Install drive belt (Scheme 84) Refer to «DRIVE BELTS - 5.9L»(ref-189655-S27970610772005091200000).
10. Install the radiator fan. Refer to «RADIATOR FAN»(ref-189656-S27247075722005091200000).
11. Fill cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
12. Connect negative battery cable.
13. Start and warm the engine. Check for leaks.

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

Scheme 81

Scheme 82

1. Disconnect the negative battery cable.
2. Drain cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
3. Remove fan/viscous fan drive assembly from water pump see scheme 56 Refer to «FAN DRIVE VISCOUS CLUTCH»(ref-189656-S33852084192005091200000). Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time. WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp. Always wear safety glasses when servicing constant tension clamps. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter and width
4. If the water pump is being replaced, do not unbolt the fan blade assembly from the thermal viscous fan drive.
5. Remove the radiator fan. Refer to «RADIATOR FAN»(ref-189656-S27247075722005091200000).
6. Remove accessory drive belt see scheme 57 Refer to «DRIVE BELTS - 3.7L / 4.7L»(ref-189655-S16761653102005091200000).
7. Remove the lower radiator hose clamp, and remove the lower hose at the water pump.
8. Remove the water pump mounting bolts. CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be damaged, resulting in leaks.
9. Remove the water pump and gasket. Discard gasket.

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

Scheme 83

Scheme 84

1. Clean the gasket mating surfaces.
2. Using a new gasket, position water pump and install the mounting bolts see scheme 58 Tighten the water pump mounting bolts to 24 N.m (18 ft. lbs.).
3. Spin the water pump to be sure that the pump impeller does not rub against the timing chain case/cover.
4. Connect the radiator lower hose to the water pump.
5. Relax the tension from the belt tensioner see scheme 57 Install the drive belt. Refer to «DRIVE BELTS - 3.7L / 4.7L»(ref-189655-S16761653102005091200000). 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. see scheme 59for the correct belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used.
6. Install the radiator fan. Refer to «RADIATOR FAN»(ref-189656-S27247075722005091200000).
7. Fill cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
8. Connect the negative battery cable.
9. Start and warm the engine. Check for leaks.

1. Disconnect battery negative cables.
2. Drain cooling system. Refer to «COOLING»(ref-189654-S13811322982005091200000).
3. Remove the accessory drive belt. Refer to «DRIVE BELTS - 5.9L DIESEL»(ref-189655-S26332597982005091200000).
4. Remove water pump mounting bolts see scheme 60
5. Clean water pump sealing surface on cylinder block.

1. Disconnect negative battery cable.
2. Drain coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
3. Remove serpentine belt.
4. Remove fan clutch assembly.
5. Remove coolant fill bottle.
6. Disconnect washer bottle wiring and hose.
7. Remove fan shroud assembly.
8. Remove A/C compressor and generator brace.
9. Remove idler pulleys.
10. Remove belt tensioner assembly.
11. Remove upper and lower radiator hoses.
12. Remove heater hoses.
13. Remove water pump mounting bolts, and remove pump.

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.
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.
8. Connect washer bottle wiring and hose.
9. Install coolant fill bottle.
10. Install fan clutch assembly.
11. Install serpentine belt.
12. Connect negative battery cable.
13. Fill coolant. Refer to «COOLING»(ref-189654-S13811322982005091200000) .
14. Pressure test coolant system.