Engine Cooling System: Other Jeep Compass I рестайлинг 2

GAS ENGINE

The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible. It also maintains normal operating temperature and prevents overheating.

The cooling system also provides a means of heating the passenger compartment. The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system. A separate and remotely mounted, coolant bottle is used.

The cooling system consists of

1. Radiator
2. Coolant
3. Cooling Fan(s)
4. Water pump
5. Thermostat
6. Hoses and clamps
7. Coolant pressure bottle/overflow system

The primary purpose of a cooling system is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. It also provides hot water (coolant) for heater performance and cooling for automatic transmission oil. It does this by transferring heat from engine metal to coolant, moving this heated coolant to the radiator, and then transferring this heat to the ambient air.

1. When the engine is cold and both the primary and secondary thermostats are closed. The coolant will circulate through the engine, heater system, and the bypass. The cooling system has no flow through the radiator
2. As the engine warms up, the primary thermostat will start to open at 77 °C (170 °F). Coolant will start to flow through the radiator and the internal transmission cooler. The primary thermostat will fully open at 95 °C (203 °F).
3. The secondary thermostat will start to open at 95 °C (203 °F). This will increase the coolant flow through the cylinder block and cylinder head and the radiator. The secondary thermostat will fully open at 104 °C (220 °F).
4. TURBOCHARGED ENGINE ONLY: the turbocharged engine has a single thermostat that starts to open at 90.5 °C (195 °F) and is fully open at 100 °C (212 °F). This is done to reduce resistance and increase flow.

Scheme 52

The water pump draws coolant from the radiator and delivers it to the engine block. The coolant travels through the engine block into the cylinder head. Coolant exits the engine at the thermostat. If the coolant temperature is less than 87°C (189°F) the thermostat directs all of the coolant back to the water pump. If the coolant temperature is between 87°C (189°F) and 102°C (216°F) the thermostat is in the mix mode and directs the coolant to the radiator and the water pump. If the coolant is greater than 102°C (216°F), the thermostat directs all of the coolant to the radiator.

The thermostat also feeds excess coolant and bleeds air from the system through a hose leading to the coolant reservoir. The reservoir returns coolant to the inlet side of the water pump. A port and hose at the rear of the engine block provides coolant to the heater core. This coolant is returned to the engine at the intake side of the water pump.

The oil cooler receives coolant directly from the engine block. A hose returns this coolant to the inlet side of the water pump.

AERATION

If coolant level drops below a certain point, aeration will occur drawing air into the water pump resulting in the following

1. High reading shown on the temperature gauge.
2. Loss of coolant flow through the heater core.
3. Corrosion in the cooling system.
4. Transmission oil will become hotter (automatic transmission equipped vehicles).
5. Water pump seal may run dry, increasing the risk of premature seal failure.
6. Combustion gas leaks into the coolant can also cause the above problems.

DEAERATION

As air is removed from the cooling system, it gathers in the coolant recovery container. This pressure is released into the atmosphere through the pressure valve located in the radiator pressure cap when pressure reaches 96 - 124 kPa (14 - 18 psi). This air is replaced with coolant from the coolant recovery container.

Note. Deaeration does not occur at engine idle, higher engine speeds are required. Normal driving will deaerate cooling system.

To effectively deaerate the system, multiple thermal cycles of the system may be required.

FLOW CHECK

To determine whether coolant is flowing through the cooling system, use one of the following procedures

1. If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If it is hot, coolant is circulating.
2. Remove pressure cap when engine is cold, remove small amount of coolant. Idle engine until thermostat opens, you should observe coolant flow while looking down the filler neck. Once flow is detected install the pressure cap.

CLEANING

Drain the cooling system and refill with water. Run the engine with the radiator cap installed until the upper radiator hose is hot. Stop the engine and drain the water from system. If the water is dirty, fill the system with water, run the engine and drain the system. Repeat this procedure until the 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.

1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be removed from pulleys (5 and 9).
2. Remove accessory drive belt (2).

DIESEL

1. Raise and support the vehicle. CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.
2. Using a wrench, rotate the belt tensioner (4) until the belt (3) can be removed from the pulleys (1, 2). Gently, release spring tension on tensioner (4).
3. Remove the accessory drive belt (3).

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

1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3).
2. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be installed on the generator pulley (3). Release spring tension onto accessory drive belt (2).

Note. When installing accessory drive belt, be sure belt is routed around all accessories correctly.

1. Install belt over all pulleys except for the power steering pump pulley. CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.
2. Using a wrench, rotate belt tensioner (4) clockwise until belt can be installed onto power steering pump pulley. Release spring tension onto belt.
3. Lower vehicle from hoist.

DIESEL ENGINE

1. Remove the accessory drive belt (3). Refer to «BELT, SERPENTINE, REMOVAL»(ref-612716-S26668951772014043000000) .
2. From under the vehicle, remove the idler pulley mounting bolt. Remove idler pulley (2).

1. Remove the accessory drive belt (3). Refer to «BELT, SERPENTINE, REMOVAL»(ref-612716-S26668951772014043000000) .
2. From under the vehicle, remove the idler pulley mounting bolt. Remove idler pulley (2).

1. Position accessory drive belt tensioner (8) and install mounting bolt (1). Tighten bolt (1) to 24 N.m (212 in. lbs.).
2. Install accessory drive belt (2). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-612716-S36648552212014043000000) .
3. Install belt splash shield (3).
4. Lower vehicle.

1. Install tensioner pulley and bolt, if removed. Tighten bolt to 25 N.m (18 ft. lbs.).
2. From underneath the vehicle, position the belt tensioner assembly (4) onto the engine.
3. Install the lower bolt (3) into the accessory drive bracket to assist in holding the tensioner assembly (4) in place. Hand tighten the bolt.
4. Lower the vehicle.
5. Install the upper belt tensioner bolts (1, 2) to the accessory drive bracket. Tighten the bolts to 20 N.m (15 ft. lbs.).
6. Tighten the lower belt tensioner bolt to 45 N.m (33 ft. lbs.).
7. Install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-612716-S36648552212014043000000) .

The coolant recovery system consists of a coolant recovery container mounted to the RH inner wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to the radiator neck, and a pressure cap.

The coolant recovery system consists of a coolant recovery container mounted to the RH inner wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to the radiator neck, and a pressure cap.

The system works in conjunction with the cooling system pressure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air. The system provides space for expansion and contraction. Also, the system provides a convenient and safe method for checking and adjusting the coolant level at atmospheric pressure without removing the pressure cap. It also provides some reserve coolant to compensate for minor leaks and evaporation or boiling losses.

The location of the container allows any air or vapor exceeding the pressure/vent cap rating to escape through the cap. Coolant flows through the container at all times during engine operation whether the engine is cold or at normal operating temperature. The coolant container is equipped with a pressure/vent cap. For more information. Refer to CAP, RADIATOR, DESCRIPTION .

Scheme 53

1. Partially drain cooling system using the draincock only. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) . Drain system below level of the coolant recovery pressure container.
2. Remove the return hose (5) from the upper radiator hose tee (3).
3. Remove the coolant recovery bottle mount bolt (2) from the mounting bracket (1).
4. Disengage the coolant recovery container (6) from the washer reservoir bottle (4).
5. Remove the coolant recovery container (6).

Scheme 54

1. Partially drain the cooling system using the draincock only. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) . Drain the system below the level of the coolant recovery pressure container (2).
2. Disconnect the return hose at the coolant recovery pressure container (2).
3. Remove the coolant recovery pressure container bolts.
4. Lift container up and disconnect the coolant hose (3) from the bottom of the pressure container (2).
5. Remove the pressure container (2) from engine compartment.

1. Position the coolant recovery container (6) into the washer fluid reservoir (4).
2. Install the coolant recovery container mounting bolt (2). Tighten the mounting bolt to 4 N.m (35 in. lbs.).
3. Connect the hose (5) at the upper radiator tee (3).
4. Fill coolant recovery container to proper level. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .

1. Lower the pressure container (2) into the engine compartment and connect the coolant hose (3) at bottom of the pressure container (2).
2. Position the pressure container (2) and install the mounting bolts. Tighten the mounting bolts to 4 N.m (35 lbs. in.).
3. Connect the coolant return hose to the coolant recovery container (2).
4. Refill the cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .

Scheme 55

The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97-124 kPa (14-18 psi).

There is also a vent valve (6) in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant recovery container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached.

Scheme 56

All vehicles are equipped with a pressure cap. This cap releases pressure at some point within approximately 110 kPa (16 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 approximately 110 kPa (16 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 57

Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester (special tool #7700, Tester, Cooling System). Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap.

If the pressure cap tests properly while positioned on Cooling System Tester (special tool #7700, Tester, Cooling System), but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly.

GAS ENGINES

Scheme 58

To find the coolant needed. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar® Antifreeze/Coolant, or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called OAT, for Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 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.

DIESEL ENGINES

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar® Antifreeze/Coolant, 5 Year/100, 000 Mile Formula (MS-9769), or the equivalent ethylene glycol based coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 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.

The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant.

Radiator fan operation is controlled by the Totally Integrated Power Module (TIPM), with inputs from the engine coolant temperature sensor, continuously variable transmission (CVT) oil temperature, and A/C head pressure. The (TIPM) turns on the fan through either the high or low speed fan relay. The PCM provides a ground to the relay's control circuit. The fan relays are located in the (TIPM). Refer to the label beneath the (TIPM) cover for location of fan relays.

If the cooling fan is inoperative or a Diagnostic Trouble Code (DTC) related to fan control has been set, for diagnostic procedures, refer to DTC INDEX .

Radiator fan operation is controlled by the Powertrain Control Module (PCM) with inputs from the temperature of the coolant, which is sensed by the coolant temperature sensor, and vehicle speed which is measured by the vehicle speed sensor. The PCM turns on the fan through either the high or low speed fan relay. The PCM provides a ground to the relay's control circuit. The fan relays are located on the back of the fan shroud.

If the cooling fan is inoperative or a Diagnostic Trouble Code (DTC) related to fan control has been set, for diagnostic procedures. Refer to DTC INDEX .

WATER PUMP

Replace water pump body assembly if it has any of these defects

1. Cracks or damage on the body.
2. Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body.
3. Loose or rough turning bearing.
4. Impeller rubs either the pump body or the engine block.
5. Impeller loose or damaged.
6. Sprocket or sprocket flange loose or damaged.

1. Position water pump assembly (1) and gasket onto cylinder block.
2. Position water inlet tube (4) and gasket onto water pump (1).
3. Install mounting bolts (2). Tighten bolts to 24 N.m (18 ft. lbs.).
4. Install drive belt splash shield.
5. Lower vehicle.
6. Install accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-612716-S36648552212014043000000) .
7. Evacuate air and refill cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
8. Check cooling system for leaks. Refer to «DIAGNOSIS AND TESTING»(ref-612716-S06015329392014043000000) .

1. Position the water/power steering pump (3) onto the engine block while guiding the thermostat bypass hose onto pump assembly.
2. Install the water/power steering pump mounting bolts (1). Tighten the bolts (1) to 20 N.m (15 ft. lbs.).
3. Install the water/power steering support bracket bolt. Tighten the bolt to 12 N.m (9 ft. lbs.).
4. Install the power steering pressure line (2). Tighten the nut to 32 N.m (24 ft. lbs.).
5. Connect the electronically controlled vacuum switch connector (4).
6. Connect the vacuum lines (3) to the electronically controlled vacuum switch.
7. Connect the coolant inlet hose (2) at the pump.
8. Connect the power steering pump supply hose (1) at the pump.
9. Connect the power steering pressure line retaining bracket bolt (2). Tighten the bolt to 12 N.m (9 ft. lbs.).
10. Connect the coolant return hose to the water pump (3). Tighten the band clamps (4) to 1.7 N.m (15 in. lbs.).
11. Install accessory drive belt (1). Refer to «BELT, SERPENTINE, INSTALLATION»(ref-612716-S36648552212014043000000) .
12. Lower the vehicle.
13. Evacuate air and refill cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
14. Fill and bleed the power steering system. Refer to «STANDARD PROCEDURE»(ref-612706-S05742878522014043000000) .
15. Connect the negative battery cable.
16. Check cooling system for leaks. Refer to «DIAGNOSIS AND TESTING»(ref-612716-S06015329392014043000000) .
17. Check the power steering system for leaks.

DIESEL COOLING MANIFOLD

1. Using a new gasket, install the cooling manifold (1). Tighten bolts (4) to 25 N.m (18 ft. lbs.).
2. Lower the engine.
3. Install the right side engine mount. Refer to «INSULATOR, ENGINE MOUNT, RIGHT, INSTALLATION»(ref-612696-S32023989842014043000000) .
4. Install the coolant recovery bottle. Refer to «BOTTLE, COOLANT RECOVERY, INSTALLATION»(ref-612716-S10151046972014043000000) .
5. Remove the support from underneath.
6. Lower the vehicle.
7. Install the coolant return hose.
8. Connect the coolant return hose to the cooling manifold (1) and tighten the band clamps.
9. Connect the coolant return hose to the water pump and tighten band clamps.
10. Install the coolant return hose to engine block bolt and securely tighten.
11. Raise and support the vehicle.
12. If equipped, install the belly pan.
13. Lower the vehicle.
14. Evacuate air and refill cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
15. Connect the negative battery cable.
16. Check cooling system for leaks. Refer to «DIAGNOSIS AND TESTING»(ref-612716-S06015329392014043000000) .

Note. It is not necessary to discharge the air conditioning system to remove the radiator.

Scheme 59

Scheme 60

Scheme 61

Scheme 62

1. Remove air intake duct (2).
2. Disconnect the negative battery cable.
3. Remove engine cover.
4. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-612692-S42044915732014043000000) . NOTE: Belly pan removal is necessary for draining the cooling system.
5. Remove lower belly pan (2).
6. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) . NOTE: Removal of the lower radiator hose can only be accessed from the top of vehicle when the cooling fan module has been removed.
7. Partially lower the vehicle.
8. Remove the front wheel and tires.
9. Remove the inner splash shields.
10. Remove the front bumper fascia/grille (2) assembly. Refer to «FASCIA, FRONT, REMOVAL»(ref-612698-S03953696392014043000000) .
11. Lower the vehicle.
12. Remove radiator fan module assembly (8). Refer to «FAN, COOLING, REMOVAL»(ref-612716-S32355363712014043000000) .
13. Disconnect the lower radiator hose.
14. Disconnect the charge air hoses (5, 7) from the charge air cooler (2).
15. Remove the bolts (4, 6) and the charge air cooler from the radiator (3).
16. Remove remaining fasteners attaching A/C condenser (1) to radiator. Position A/C condenser aside.
17. Lift the radiator up and out of engine compartment.

1. Install the lower air seal to radiator.
2. Position radiator into mounting position.
3. Position A/C condenser against radiator. Hand start fasteners.
4. Install radiator fan/shroud assembly. Hand start fasteners.
5. Tighten all condenser fasteners to 8 N.m (70 in. lbs.).
6. Tighten all radiator fan fasteners to 6 N.m (55 in. lbs.).
7. Install fasteners attaching transmission oil cooler to radiator. Tighten fasteners to 8 N.m (70 in. lbs.).
8. Raise vehicle on hoist.
9. Connect the lower air seal to the side air seals.
10. Connect lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.
11. Connect the radiator fan electrical connector.
12. Connect the power steering hoses.
13. Close radiator draincock.
14. Lower vehicle.
15. Connect upper radiator hose. Align the hose and position the clamp to prevent interference with the engine or hood.
16. Install upper radiator closure panel and center brace Refer to «PANEL, CLOSURE, UPPER, INSTALLATION»(ref-612710-S28066290942014043000000) .
17. Install grille.
18. Install battery tray and battery.
19. Connect positive battery cable. Connect negative battery cable.
20. Install air cleaner housing assembly.
21. Fill cooling system with coolant. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
22. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

Note. Care must be taken not to damage the radiator cooling fins and tubes during installation.

1. Lower radiator (1) into mounting position.
2. Install the A/C condenser onto radiator mounts.
3. Position charge air cooler to radiator. Tighten bolts (4, 6) to 8 N.m (70 in. lbs.).
4. Connect charge air cooler hoses (5, 7).
5. Install the lower radiator hose. Align the hose and position the clamp so it will not interfere with engine components.
6. Install radiator cooling module (8). Refer to «FAN, COOLING, INSTALLATION»(ref-612716-S03927958782014043000000) .
7. Raise the vehicle.
8. Install the lower belly pan (2).
9. Partially lower the vehicle.
10. Install the front bumper/grille fascia (2). Refer to «FASCIA, FRONT, INSTALLATION»(ref-612698-S00050582162014043000000) .
11. Install inner well splash shields.
12. Install the front tires. Refer to «INSTALLATION»(ref-612693-S31957631432014043000000) .
13. Lower the vehicle.
14. Fill cooling system with appropriate coolant. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
15. Connect the negative battery cable.
16. Install engine cover.
17. Install air cleaner intake duct (2).
18. Operate engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

Scheme 63

There are two engine coolant sensors (ECT). One ECT (1) is located in the coolant adapter and one is (ECT) sensor (1) threads into the cylinder block. New sensors have sealant applied to the threads.

Scheme 64

The ECT Sensor is a Negative Thermal Coefficient (NTC) Sensor. The resistance of the ECT Sensor changes as coolant temperature changes. This results in different input voltages to the PCM. The PCM also uses the ECT Sensor input to operate the radiator cooling fan(s), and send a message over the PCI bus to the instrument cluster for temperature gauge operation.

The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is located on the top of the thermostat housing.

The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

COOLANT ADAPTER MOUNTED

1. Disconnect negative battery cable.
2. Partially drain cooling system below level of ECT Sensor (1). Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
3. Disconnect ECT Sensor electrical connector.
4. Remove ECT Sensor (1) By pressing the locking tab down and turning the sensor counterclockwise.

Scheme 65

1. Disconnect the negative battery cable.
2. Remove the thermostat housing. Refer to «THERMOSTAT, REMOVAL»(ref-612716-S13397237392014043000000) .
3. Remove retaining clip and the coolant temperature sensor (1).
4. Remove and discard the O-ring seal.

1. Lubricate the ECT sensor O-ring with coolant.
2. Install the ECT Sensor (1). Make sure the coolant sensor is locked in place.
3. Connect the ECT Sensor electrical connector.
4. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
5. Connect the negative battery cable.

1. Clean the O-ring sealing surfaces.
2. Using a new O-ring seal, install coolant temperature sensor (1) and retaining clip.
3. Install the thermostat housing. Refer to «THERMOSTAT, INSTALLATION»(ref-612716-S17147548682014043000000) .
4. Connect the negative battery cable.
5. Start engine and inspect for leaks.

Scheme 66

The primary thermostat is located on the front of the water plenum in the thermostat housing/coolant inlet. The thermostat has an air bleed vent located on its flange. The air bleed vent (1) and the locator dimple on thermostat seal provide for proper positioning of thermostat in inlet housing.

The secondary thermostat is located in the cylinder head under the water plenum.

PRIMARY THERMOSTAT - GAS ENGINE

1. Position thermostat into the water plenum, aligning air bleed with the location notch on inlet housing (2).
2. Install inlet housing (2) onto coolant adapter. Tighten bolts to 9 N.m (79 in. lbs.).
3. Connect coolant hose (1).
4. Install air filter housing.
5. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .

SECONDARY THERMOSTAT - GAS ENGINE

1. Position the thermostat into the cylinder head.
2. Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter. Replace O-ring as necessary.
3. Lubricate the O-rings with soapy water.
4. Position the coolant adapter on the water pump inlet tube and the cylinder head.
5. Install the coolant adapter mounting bolts. Tighten the bolts to 18 N.m (159 in. lbs.).
6. Connect the front coolant hose (1).
7. Connect the two rear coolant hoses (1).
8. Connect the radiator hose (3).
9. Install the air filter housing Refer to «2.0L BODY, AIR CLEANER, INSTALLATION»(ref-612695-S20867479562014043000000) or «2.4L BODY, AIR CLEANER, INSTALLATION»(ref-612697-S06236736642014043000000) .
10. Fill the cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .

Note. Use coolant on the seals of the thermostat housing so the seals wont become damaged and to help aid in installation.

1. Install the thermostat housing (2) into the accessory carrier bracket (1) by using hand pressure and twisting motion to seat the housing into place.
2. Install the two thermostat housing mounting bolts (2). Tighten the bolts to 9 N.m (80 in. lbs.).
3. Connect the thermostat heater connector (1).
4. Install the EGR (3) and the inlet nozzle (1). Install two bolts (2) to support nozzle and EGR in place. Do not tighten.
5. Raise vehicle.
6. Install all mounting screws (2) for the EGR throttle control housing and the inlet nozzle, to the mixing tank. Tighten bolts (2) to 9 N.m (80 in. lbs.).
7. Install the brake booster check valve vacuum line at the pump.
8. Install the water/power steering pump assembly. Refer to «PUMP, WATER, INSTALLATION»(ref-612716-S10572020852014043000000) .
9. Install the main drive belt (3).
10. Lower vehicle.
11. Install lower thermostat housing hose clamp onto combination water/power steering pump.
12. Connect the EGR throttle control and charge air temperature sensor connectors (1).
13. Install the upper brake booster vacuum line bracket bolt (1).
14. Install the front lower air charge hose (2). Tighten hose clamps to 2 N.m (18 in. lbs.).
15. Install the front upper air charge hose (1). Tighten hose clamps to 2 N.m (18 in. lbs.).
16. Install the fan module assembly. Refer to «FAN, COOLING, INSTALLATION»(ref-612716-S03927958782014043000000) .
17. Add coolant. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
18. Add power steering fluid. Refer to «STANDARD PROCEDURE»(ref-612706-S05742878522014043000000) .
19. Connect the negative battery cable.
20. Run engine to operating temperature and check for leaks.

Scheme 67

The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing.

1. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-612716-S12637819952014043000000) .
2. Remove the coolant adapter and secondary thermostat. Refer to «THERMOSTAT, REMOVAL»(ref-612716-S13397237392014043000000) .
3. Raise and support vehicle.
4. Remove inlet tube mounting nuts (1).
5. Remove inlet tube (2).

Check the external cooler for debris on the cooling fin surfaces. Clean as necessary.