Cooling System Specifications & Drive Belt Routing Dodge Pickup R1500

COOLING SYSTEM DRAINING

Scheme 1

Scheme 2

1. Attach one end of a hose to the draincock. Put the other end into a clean container.
2. Do not remove the radiator cap when draining the coolant from the reservoir/overflow tank. Open radiator draincock and when the tank is empty, remove the radiator cap and continue draining the cooling system.
3. If draining the entire engine, remove the cylinder block drain plugs. (Scheme 1)and (Scheme 2).

5.9L Diesel

1. Start the engine and place the heater control temperature selector in the Full-On position.
2. Turn the ignition off.
3. Do not remove radiator cap when draining coolant from reserve/overflow tank. Open radiator drain plug and when tank is empty, remove radiator cap. If the coolant reserve/overflow tank does not drain. The coolant need not be removed from tank unless the system is being refilled with fresh mixture.
4. Remove radiator pressure cap.

SRT-10

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

1. Attach one end of a hose to the draincock. Put the other end into a clean container.
2. Do not remove the radiator cap when draining the coolant from the reservoir/overflow tank remove the radiator cap and continue draining the cooling system. Open radiator draincock and when the tank is empty.
3. If draining the entire engine, remove the cylinder block drain plugs. (Scheme 1)

All Gas Engines

Note. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. See COOLING SYSTEM CLEANING/REVERSE FLUSHING .

1. Install the cylinder block drain plugs. Coat the threads with Mopar® Thread Sealant with Teflon.
2. Close the radiator petcock.
3. Fill system using a 50/50 mixture antifreeze and water. Fill the degas container pass the COLD FILL line to the top.
4. Fill coolant reserve/overflow tank to MAX mark on bottle.
5. Start and operate the engine until the thermostat opens (upper radiator hose is warm to the touch).
6. If necessary, add antifreeze mixture to the coolant reserve/overflow tank. This is done to maintain coolant level between the MAX and MIN marks. The level in the reserve/overflow tank may drop below the MIN mark after three or four warm-up and cool-down cycles.

Note. The diesel engine is equipped with two one-way check valves (jiggle pins). The check valves are used as a servicing feature and will vent air when the system is being filled. Water pressure (or flow) will hold the valves closed.

1. Close radiator drain plug.
2. Fill the cooling system with a 50/50 mixture of water and antifreeze.
3. Fill coolant reserve/overflow tank to the FULL mark.
4. Start and operate engine until thermostat opens. Upper radiator hose should be warm to touch.
5. If necessary, add 50/50 water and antifreeze mixture to the coolant reserve/overflow tank to maintain coolant level. This level should be between the ADD and FULL marks. The level in the reserve/overflow tank may drop below the ADD mark after three or four warm-up and cool-down cycles.

Note. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. Clean cooling system prior to refilling. See COOLING SYSTEM CLEANING/REVERSE FLUSHING .

1. Install cylinder block drain plugs. Coat the threads with Mopar® Thread Sealant with Teflon.
2. Close radiator petcock.
3. Fill cooling system with a 50/50 mixture of water and antifreeze.
4. Fill coolant reserve/overflow tank to MAX mark on indicator stick.
5. Start and operate engine until thermostat opens (upper radiator hose warm to touch).
6. If necessary, add a 50/50 water and antifreeze mixture to the coolant reserve/overflow tank. This is done to maintain coolant level between the MAX and MIN marks. The level in the reserve/overflow tank may drop below the MIN mark after three or four warm-up and cool-down cycles.

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 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

The coolant reserve/overflow system provides a quick method for determining the coolant level without removing the radiator pressure cap. With the engine at normal operating temperature and idling, observe the level of the coolant on the external level indicator on the side of the coolant reserve/overflow bottle. The coolant level should be between the MIN and MAX marks. If the coolant is below the MIN mark, add a 50/50 mixture of antifreeze and water to the bottle until the level reaches the MIN mark. Do Not Overfill the bottle by adding fluid above the MAX line. This may cause coolant to spill onto the ground during subsequent vehicle operation.

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.

Reverse Flushing

Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done using air pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty systems with evidence of partial plugging.

Reverse Flushing Radiator

Disconnect radiator hoses from radiator inlet and outlet. Attach a section of radiator hose to radiator bottom outlet fitting and insert flushing gun. Connect a water supply hose and air supply hose to flushing gun.

Allow radiator to fill with water. When radiator is filled, apply air in short blasts. Allow radiator to refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. Have radiator cleaned more extensively by a radiator repair shop.

Reverse Flushing Engine

Drain cooling system. Remove thermostat housing and thermostat. Install thermostat housing. Disconnect radiator upper hose from radiator and attach flushing gun to hose. Disconnect radiator lower hose from water pump and attach a lead-away hose to water pump inlet fitting.

Connect water supply hose and air supply hose to flushing gun. Allow engine to fill with water. When engine is filled, apply air in short blasts, allowing system to fill between air blasts. Continue until clean water flows through the lead away hose.

Remove lead away hose, flushing gun, water supply hose and air supply hose. Remove thermostat housing and install thermostat. Install thermostat housing with a replacement gasket. Connect radiator hoses. Refill cooling system with correct antifreeze/water mixture. See COOLING SYSTEM FILLING .

Specifications & Procedures

BELT ADJUSTMENT SPECIFICATIONS

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

DRIVE BELTS

When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Belt Wear Patterns), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. (Scheme 8)

Scheme 8

Removal (3.7L & 4.7L)

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

1. Disconnect negative battery cable from battery. Rotate belt tensioner until it contacts it's stop.
2. Remove belt, then slowly rotate the tensioner into the free-arm position. (Scheme 3)

Removal (5.7L)

1. Remove the air intake tube between intake manifold and air filter assembly.
2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys. (Scheme 4)
3. Remove belt.
4. Gently release tensioner.

Removal (5.9 Diesel)

The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment.

Drive belts on diesel engines are equipped with a spring loaded automatic belt tensioner, displays the tensioner for vehicles without air conditioning. This belt tensioner will be used on all belt configurations, such as with or without air conditioning. See BELT TENSIONERS .

1. A 1/2" square hole is provided in the automatic belt tensioner. Attach a 1/2" drive-long handle ratchet to this hole.
2. Rotate ratchet and tensioner assembly clockwise until tension has been relieved from belt. (Scheme 5)and (Scheme 6).
3. Remove belt from water pump pulley first.
4. Remove belt from vehicle.

Removal (SRT-10)

1. Remove the air intake tube between intake manifold and air filter assembly.
2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys.
3. Remove accessory drive belt.
4. Gently release tensioner. (Scheme 7)

Installation (3.7L & 4.7L)

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

1. Check condition of all pulleys.
2. Install new belt. Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it's stop position. Route the belt around the idler 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.94 INCH (24 mm). If the measurement exceeds this specification replace the serpentine accessory drive belt. (Scheme 9)

Installation (5.7L)

Note. When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.

1. Position the drive belt over all pulleys except for the water pump pulley. (Scheme 4)
2. Rotate tensioner counterclockwise and slip the belt over the water pump pulley.
3. Gently release tensioner.
4. Install the air intake tube between intake manifold and air filter assembly.

Installation (5.9 Diesel)

1. Position drive belt over all pulleys except water pump pulley.
2. Attach a 1/2" ratchet to tensioner.
3. Rotate ratchet and belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys.

Installation (SRT-10)

Note. When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.

1. Position the drive belt over all pulleys except for the water pump pulley. (Scheme 7)
2. Rotate tensioner counterclockwise and slip the belt over the water pump pulley.
3. Gently release tensioner.
4. Install the air intake tube between intake manifold and air filter assembly.

BELT TENSIONERS

Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life.

It is not necessary to adjust belt tension on the 3.7L engines. These engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. (Scheme 9)

Scheme 9

On 3.7L and 4.7L engines, the tensioner 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 .94" (24 mm) 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.

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. See «DRIVE BELTS»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing__drive-belts).
2. Remove tensioner assembly from mounting bracket. (Scheme 10)
3. Remove pulley bolt. Remove pulley from tensioner.

Scheme 10

1. Remove accessory drive belt.
2. Remove tensioner and mounting bracket
3. Remove the tensioner assembly from the mounting bracket. (Scheme 11)

Removal (5.9L Diesel)

Scheme 11

1. Remove accessory drive belt. See «DRIVE BELTS»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing__drive-belts) .
2. Remove tensioner mounting bolt and remove tensioner.

Scheme 12

1. Remove the air intake tube between intake manifold and air filter assembly.
2. Release the belt tension by rotating the tensioner counterclockwise with a 15 mm wrench on the tensioner pulley bolt. Rotate belt tensioner until belt can be removed from pulleys.
3. Remove accessory drive belt. See «DRIVE BELTS»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing__drive-belts).
4. Gently release tensioner.
5. Remove tensioner mounting nut. see scheme 13

1. Install pulley and pulley bolt to tensioner. Tighten bolt to 45 ft. lbs. (61 N.m).
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 30 ft. lbs (41 N.m).
3. Install accessory drive belt.
4. Check belt indexing marks. (Scheme 9)

1. Install tensioner on to the mounting bracket. Tighten bolt to 30 ft. lbs. (41 N.m).
2. Install tensioner and bracket assembly.
3. Install accessory drive belt.

1. Install tensioner assembly to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 32 ft. lbs. (43 N.m).
2. Install drive belt. See «DRIVE BELTS»(/dodge/pickup-r1500/1997-2012/remont/cooling-system-mechanical/#cooling-system-specifications-drive-belt-routing__drive-belts) .

Note. When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys.

1. Install tensioner and mounting nut. Torque mounting nut to 30 ft. lbs. (41 N.m).
2. Install accessory drive belt.
3. Install the air intake tube between intake manifold and air filter assembly.

COOLING SYSTEM SPECIFICATIONS

See also:
• COOLING SYSTEM CLEANING/REVERSE FLUSHING
• BELT TENSIONERS
• DRIVE BELTS