Cooling System - Engine & Transmission: Other RAM Pickup 2500

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. Overloaded Truck
4. Slow traffic
5. Traffic jams
6. High speed or steep grades
7. Snow Plow restricting airflow through cooling module
8. Debris on front of the grill or the cooling module that is restricting airflow

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 up to 2000 RPM with transmission in park or neutral for more airflow is recommended.
3. If equipped with a snow plow. Activate the snow plow mode.

TRAILER TOWING

Consult Trailer Towing section of the owners manual. Do not exceed the limits.

RECENT SERVICE OR ACCIDENT REPAIR

Determine if any recent service has been performed on vehicle that may affect the 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).
6. Service to electrically controlled viscous fan clutch

Note. If investigation reveals none of the previous items as a cause for an engine overheating complaint, refer to the COOLING SYSTEM DIAGNOSIS CHART.

These charts are to be used as a quick-reference only.

COOLING SYSTEM DIAGNOSIS CHART

Scheme 44

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 the engine until the radiator upper hose is warm to the touch. Aim the commercially available black light tool at the components to be checked. If leaks are present, the 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 .

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 the coolant level. Push down on the cap to disengage it from the stop tabs. Wipe the inside of the 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 the cams on the outside of the filler neck. If the cams are damaged, seating of the pressure cap valve and tester seal will be affected.

Attach pressure tester ((special tool #7700, Tester, Cooling System) or an equivalent) to radiator filler neck.

Operate the tester pump to apply 103.4 kPa (15 psi) pressure to the system. If the hoses enlarge excessively or bulges while testing, replace as necessary. Observe the gauge pointer and determine the condition of the cooling system according to following criteria

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 of the connections for seepage or slight leakage with a flashlight. Inspect the radiator, hoses, gasket edges and heater. Seal the small leak holes with a Sealer Lubricant (or equivalent). Repair the leak holes and inspect the system again with pressure applied.

Drops Quickly: Indicates that serious leakage is occurring. Examine the system for external leakage. Block side panels are embossed to highlight core plugs. Remove embossed noise panels to inspect and or repair core plugs. If leaks are not visible, inspect for internal leakage.

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.

Scheme 45

DO NOT WASTE reusable coolant. If solution is clean, drain 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. 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 (1).

Scheme 46

Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components.

Note. To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system.

Note. The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system.

Note. For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor).

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps.
2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank.
3. Attach the adapter cone (2) to the vacuum gauge (1).
4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1).
5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly.
6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum.
8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse.
9. Close the vacuum generator/venturi ball valve.
10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly.
11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated.
12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system.
13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2).
14. Open the suction hose's ball valve to begin refilling the cooling system.
15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached.
16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly.
17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank.
18. With heater control unit in the HEAT position, operate engine with container cap in place.
19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container.
20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period.
21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap.

STANDARD PROCEDURE - FILLING

Note. Cooling system fill procedure is critical to overall cooling system performance.

Note. Make sure all hoses are connected and radiator draincock is closed. Draincock should be hand tightened only.

6.7L

Scheme 51

Scheme 52

1. Close radiator drain plug.
2. Remove the vent fitting (1) located near the EGR cooler (2).
3. If using funnel 8195: Remove cooling system pressure cap. Attach Filling Aid Funnel (special tool #8195, Funnel) , to coolant pressure container filler neck. Use the supplied clip to pinch overflow hose. Pour coolant into the larger section of Filling Aid Funnel (the smaller section of funnel is to allow air to escape). Continue filling until a steady stream of coolant flows from the vent hole. Install vent fitting when coolant is free of bubbles. Tighten the bleed plug to 6 N.m (55 in. lbs.). Remove clip from overflow hose. Allow coolant in Filling Aid Funnel to drain into overflow chamber of pressure container. Remove Filling Aid Funnel. (special tool #8195, Funnel) Install the pressure cap. 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. NOTE: The 8195A does not require pinching off the overflow hose. The adapter seal prevents liquid from entering the overflow during coolant fill.
4. If using Special Tool 8195A: Select the appropriate fitting extension (3) and locking ring (2) and attach to the fill neck of the cooling system. Make sure the adapter seal fits firmly against the inside of the fill neck base to ensure a good seal. After the extension and locking ring are installed, make sure the extension can not be moved. This will confirm a good seal. Attach the funnel (1) to the extension (1) and fill with coolant. Add coolant to the funnel. Continue to add coolant until a steady stream of coolant flows from the vent hole. Install the vent fitting when coolant is free of bubbles. Tighten the vent fitting to 6 N.m (55 in. lbs.). Install the stopper (4) into the funnel base. The stopper will prevent the fluid that is left in the funnel from spilling out when separated from the extension. Remove the funnel, extension and locking ring and install the cap.
5. Start and operated the engine. Take the vehicle on a test drive till operating temperature is reached. Shut the engine down and wait till engine is cool.
6. Slowly loosen vent fitting (1) to purge any trapped air. If air is still present. Repeat step 3 - 5.
7. Check coolant level in coolant recovery container. Fill to FULL line.
8. The volume of coolant added to the engine must be within 1.5 quarts of the volume drained. If this requirement has not been met, repeat steps 2 - 9.
9. Remove Tool . Install radiator cap.

5.9L

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.

Scheme 53

Clean cooling system prior to refilling. Refer to Standard Procedure .

1. Close radiator drain plug.
2. If using funnel 8195: Remove cooling system pressure cap. Attach Filling Aid Funnel (special tool #8195, Funnel), to coolant pressure container filler neck. Use the supplied clip to pinch overflow hose. Pour coolant into the larger section of Filling Aid Funnel (the smaller section of funnel is to allow air to escape). Add coolant until some coolant remains in the funnel and no more air bubbles appear in the fluid. Remove clip from overflow hose. Allow coolant in Filling Aid Funnel to drain into overflow chamber of pressure container. Remove Filling Aid Funnel. (special tool #8195, Funnel) Install the pressure cap. NOTE: The 8195A does not require pinching off the overflow hose. The adapter seal prevents liquid from entering the overflow during coolant fill.
3. If using Special Tool 8195A: Select the appropriate fitting extension (3) and locking ring (2) and attach to the fill neck of the cooling system. Make sure the adapter seal fits firmly against the inside of the fill neck base to ensure a good seal. After the extension and locking ring are installed, make sure the extension can not be moved. This will confirm a good seal. Attach the funnel (1) to the extension (3) and fill with coolant. Add coolant to the funnel. Continue to add coolant until it is free of bubbles. Install the stopper (4) into the funnel base. The stopper will prevent the fluid that is left in the funnel from spilling out when separated from the extension. Remove the funnel, extension and locking ring and install the cap.
4. Fill coolant recovery container to the FULL mark.
5. Start and operate engine until thermostat opens. Upper radiator hose should be warm to touch.
6. Accelerate engine from idle to 2500 RPM five times.
7. Shut off engine. Allowing cooling system to settle. Fill coolant recovery container to FULL line.
8. Start and operate engine. Take vehicle for a test drive till operating temperature is reached.
9. Shut off engine. Allow engine to cool. Fill coolant recovery container to FULL line.
10. The volume of coolant added to the engine must be within 1.5 quarts of the volume drained. If this requirement has not been met, repeat steps 1 - 13.
11. Install radiator cap.

FILL VOLUMES

5.7L ENGINE

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 accessory drive belt (4) over all pulleys (1,2,3,5,6) except for the water pump pulley (8).
2. Rotate the tensioner (7) clockwise and slip the belt over the water pump pulley (8).
3. Gently release the tensioner (7).

6.7L DIESEL ENGINE

1. Position drive belt over all pulleys except water pump pulley.
2. Attach a suitable tool to the accessory drive belt tensioner. 1 - IDLER PULLEY 2 - ACCESSORY DRIVE BELT 3 - P/S PULLEY 4 - RADIATOR FAN PULLEY 5 - CRANKSHAFT PULLEY 6 - ACCESSORY DRIVE BELT TENSIONER 7 - GENERATOR 8 - WATER PUMP
3. Rotate accessory drive belt tensioner clockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove tool. Be sure belt is properly seated on all pulleys.

1. Remove the accessory drive belt (4). Refer to «TENSIONER, Belt , Removal»(ref-457792-S17039236212012030200000) .
2. Remove the bolt from the idler pulley (2).
3. Remove the idler pulley (2).

3.7L/4.7L ENGINE

1. The idler pulley is serviced as part of the belt tensioner assembly. For removal steps, refer to «TENSIONER, Belt , Removal»(ref-457792-S17039236212012030200000) .

1. Position the idler pulley (2).
2. Install the idler pulley (2) bolt. Tighten the bolt to 54 N.m (40 ft. lbs.).
3. Install the accessory drive belt (4). Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .

1. The idler pulley is serviced as part of the belt tensioner assembly. For installation steps, refer to «TENSIONER, Belt , Installation»(ref-457792-S09501515412012030200000) .

1. Remove the accessory drive belt (4). Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
2. Remove the bolt from the belt tensioner assembly (7).
3. Remove the belt tensioner assembly (7).

Scheme 54

1. Remove accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
2. Remove tensioner mounting bolt and remove tensioner (7).

1. An indexing slot is located on back of tensioner (3). Align this slot to the head of the bolt on the front cover. Install the mounting bolt. Tighten bolt (2) to 41 N.m (30 ft. lbs.).
2. Install accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
3. Check tensioner indexing marks.

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 belt tensioner assembly (7) onto the front of the engine block. Tighten the bolt to 41 N.m (30 ft. lbs.).
2. Install the accessory drive belt (4). Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .

1. Install tensioner assembly (7) to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 N.m (32 ft. lbs.) torque.
2. Install drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .

Scheme 55

The coolant recovery/overflow bottle (2) is mounted on the front of the radiator support and behind the grille. The coolant recovery/overflow bottle (2) is made of high temperature plastic.

3.7L/4.7L/5.7L ENGINE

1. Remove the exterior grille. Refer to «GRILLE , Removal»(ref-457777-S02947677742012030200000) .
2. Partially drain the cooling system using the draincock only. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) . NOTE: DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
3. Drain system below the level of the coolant recovery pressure container.
4. Remove the recovery hose (1) from the radiator.
5. Remove the coolant recovery bottle (2) to radiator support mounting bolts.
6. Disengage the coolant recovery bottle (2) mounting pins located on the radiator support side by pulling the assembly straight up.
7. Remove the coolant recovery bottle (1).

Scheme 56

1. Disconnect and isolate the negative battery cable.
2. If equipped, disconnect and isolate the negative battery cable from the auxiliary battery.
3. Partially drain coolant until the coolant recovery bottle (3) and overflow hose (2) are completely empty.
4. Remove the overflow hose (2) from the coolant recovery bottle (3).
5. Remove the mounting bolts (1).
6. Remove coolant recovery bottle (3) from the vehicle.

1. Align the coolant recovery bottle (2) mounting pins into the slots located on the radiator support side and push the coolant recovery bottle (2) into place. NOTE: Ensure that the mounting pins are properly seated into the radiator support.
2. Install the coolant recovery bottle (2) to radiator support bolts. Tighten the bolts to 10 N.m (89 in. lbs).
3. Connect the recovery hose (1) to the radiator.
4. Install the front grille. Refer to «GRILLE , Installation»(ref-457777-S17835290622012030200000) .
5. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
6. Test the system for leaks. Refer to «Diagnosis and Testing»(ref-457792-S26721215612012030200000) .

6.7L DIESEL

1. Position the coolant recovery bottle (3) into the vehicle.
2. Install mounting bolts (1). Tighten to 8.5 N.m (75 in. lbs).
3. Install overflow hose (2) onto the coolant recovery bottle (3).
4. Fill the coolant recovery bottle (3) with coolant until the required level is met.
5. If equipped, connect the negative battery cable to the auxiliary battery.
6. Connect the negative battery cable.

Scheme 57

All cooling systems are equipped with a pressure cap. For all engines, the pressure cap is located on top of the radiator outlet tank. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 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 97-to-124 kPa (14-to-18 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.

RADIATOR CAP-TO-FILLER NECK SEAL

The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool (special tool #7700, Tester, Cooling System) (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi).

Do not remove the radiator cap at any time except for the following purposes

1. Check and adjust antifreeze freeze point.
2. Refill the system with new antifreeze.
3. Conducting service procedures.
4. Checking for vacuum leaks.

Scheme 58

Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester (special tool #7700, Tester, Cooling System) or an equivalent. (Scheme 56)

Operate the tester pump to 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 cap. Refer to the following CAUTION .

The pressure cap may test properly while positioned on tool (special tool #7700, Tester, Cooling System) (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly.

Scheme 59

Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. see scheme 42 A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap.

Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator.

COOLANT PERFORMANCE

The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows

Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion.

100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in severe engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water.

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

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.
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 - 85° - 91° C (185° - 195° F) 4.7L Manual - 74° - 79° C (165° - 175° F) 5.7L Automatic Standard Cool - 94° C - 99°C (201° F - 211° F) 5.7L Manual - 93° C - 100°C (199° F - 212° F) 5.7L Heavy Duty Snowplow - 76° C - 83°C (169° F - 181° 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: 3.7L Automatic - 76°C - 81°C (168° F - 178° F) 3.7L Manual/4.7L Auto - 67°C - 73°C (153° F - 163° F) 4.7L Manual - 56°C - 62°C (133° F - 143° F) 5.7L Automatic Standard Cool - 69° C - 74°C (156° F - 166° F) 5.7L Manual - 71° C - 76°C (160° F - 170° F) 5.7L Heavy Duty Snowplow - 55° C - 60°C (168° F - 178° F) A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit.

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

Scheme 60

If the fan assembly does not free-wheel and a metallic grinding sound exists, replace the electronically controlled fan drive. Refer to FAN, Cooling, Electric , Removal or FAN, Cooling, Viscous , Removal .

Note. The following test may take up to 15 minutes to perform.

The engine should be at normal operating temperature.

1. Set the parking brake and verify the transmission is in park or neutral.
2. Set air conditioner (if equipped) and blower fan to OFF.
3. Start and allow engine to reach normal operating temperatures.
4. Stop engine, connect the scan tool and select appropriate model year and engine option.
5. Check for and correct existing DTC's
6. Locate the electronically controlled viscous fan drive connector on the fan shroud. WARNING: A spark may occur when the connection to battery is made. Be sure there are no combustible materials near the area where this procedure is being performed.
7. Using a jumper wire, backprobe pin 6 of the viscous fan drive connector to battery positive. NOTE: The fan drive control coil is energized to 12 volts at this time.
8. Using the scan tool, confirm that DTC 0480 is set to verify a good connection at the cooling fan harness connector.
9. Start the engine.
10. Actuate engine speed to 2000 RPM.
11. Go to the SENSOR screen and observe the fan speed.
12. Run the engine at 2000 RPM until the fan speed increases to 1850 RPM or more for 30 seconds. NOTE: Fan RPM may ramp up slowly. NOTE: It maybe take 15 minutes before fan speed increases.
13. The fan speed should be in accordance to the «VISCOUS FAN DRIVE SPEEDS»(ref-457792-S11059095832012031500000) table below.
14. If fan speed does not increase, make sure that the jumper wire has a good connection. If so replace the electronically control viscous fan drive.
15. If the fan speed does increase and there is still a concern, refer to the appropriate Engine Performance Electrical Diagnostics article to diagnosis the electronically controlled viscous fan drive control circuit.

VISCOUS FAN DRIVE SPEEDS

Scheme 61

1. Do Not attempt to remove the fan/viscous fan drive assembly (2) from the vehicle at this time. CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction.
2. Disconnect negative battery cable from battery.
3. The thermal viscous fan drive/fan blade assembly (2) is attached (threaded) to the water pump hub shaft. Remove the fan blade/viscous fan drive assembly from the water pump by turning the mounting nut clockwise as viewed from the front. Threads on the viscous fan drive are LEFT-HAND. A 36 MM Fan Wrench (1) should be used to prevent pulley from rotating.
4. Do Not unbolt the fan blade assembly from viscous fan drive at this time.
5. Remove the fan shroud-to-radiator mounting bolts.
6. Pull the lower shroud mounts out of the radiator tank clips.
7. Remove the fan shroud, electric cooling fan, and fan blade/viscous fan drive assembly (2) as a complete unit from vehicle. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) or «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) .
8. After removing the fan blade/viscous fan drive assembly (2), 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.
9. Remove four bolts securing fan blade assembly to viscous fan drive.

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

1. Remove the upper radiator shroud (1).
2. Disconnect and isolate the battery negative cable.
3. If equipped, disconnect and isolate the negative battery cable from the auxiliary battery.
4. Disconnect the electronically controlled viscous fan electrical connector (2) at the fan shroud.
5. Remove and reposition the fan drive wire harness support (1) from the fan shroud.
6. Remove the two fan shroud-to-radiator shroud mounting bolts (3) located on the driver side of the vehicle.
7. Remove the fan shroud-to-radiator shroud mounting bolt (2) located on the passenger side of the vehicle.
8. Remove the fan shroud-to-lower radiator shroud push pins. CAUTION: Do not remove the fan pulley bolts. This pulley is under spring tension.
9. The electronically controlled viscous fan drive/fan blade assembly is attached (threaded) to the fan pulley shaft. 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 36 MM Fan Wrench can be used. Place a bar or screwdriver between the fan pulley bolts to prevent pulley from rotating.
10. Disengage the fan shroud lower retaining clips.
11. Collapse fan shroud toward front of vehicle and remove fan drive/fan blade and fan shroud as an assembly.
12. Remove the electrical connector bracket (2) by disengaging the retainer clip and sliding the connector bracket (2) out of the fan shroud (1). CAUTION: The electronically controlled viscous fan drive is vibration and impact sensitive, especially at the electrical connectors. Do not drop the unit.
13. Remove the four fan blade mounting bolts (2) from the viscous fan drive (3).
14. Inspect the fan for cracked, chipped or damaged fan blades (1).

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

3.7L/4.7L/5.7L

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. Install fan blade assembly (2) to the viscous fan drive. Tighten the bolts to 24 N.m (18 ft. lbs.) torque.
2. Position the fan shroud, electric cooling fan and the fan blade/viscous fan drive assembly (2) to the vehicle as a complete unit. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) or «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
3. Install the fan shroud.
4. The thermal viscous fan drive/fan blade assembly is attached (threaded) to the water pump hub shaft. Install the fan blade/viscous fan drive assembly to the water pump by turning the mounting nut counterclockwise as viewed from the front. Threads on the viscous fan drive are LEFT-HAND. A 36 MM Fan Wrench (1) should be used to prevent pulley from rotating. Tighten mounting nut to 50 N.m (37 ft. lbs.).
5. Connect the negative battery cable.

1. Install the fan blade assembly (1) to the electrically controlled viscous fan drive (3). Tighten the mounting bolts (2) to 24 N.m (18 ft. lbs.) torque.
2. Position the fan/fan drive assembly inside fan shroud (1).
3. Install the electrical connector bracket (2) by sliding the connector bracket (2) into the fan shroud (1) and engaging the retainer clip.
4. Tilt the fan shroud/fan blade toward front of vehicle and position the fan shroud/fan blade as an assembly into the engine compartment.
5. Engage the fan shroud lower retaining clips.
6. Install the fan blade/fan drive assembly to the fan pulley by turning the mounting nut clockwise (as viewed from front). The threads on the viscous fan drive are RIGHT-HAND. A 36 MM Fan Wrench can be used. Place a bar or screwdriver between the fan pulley bolts to prevent pulley from rotating. Tighten the mounting nut to 115 N.m (85 ft. lbs.) torque.
7. Install the fan shroud-to-lower radiator shroud push pins.
8. Install the fan shroud-to-radiator shroud mounting bolt (2) located on the passenger side of the vehicle. Tighten the bolt (2) to 24 N.m (18 ft. lbs.).
9. Install the two fan shroud-to-radiator shroud mounting bolts (3) located on the driver side of the vehicle. Tighten the bolts (3) to 24 N.m (18 ft. lbs.).
10. Position and connect the fan drive wire harness support (1) to the fan shroud.
11. Connect the electronically controlled viscous fan electrical connector (2) at the fan shroud.
12. If equipped, connect the negative battery cable to the auxiliary battery.
13. Connect the negative battery cable.
14. Install the upper radiator shroud (1). 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.
15. Start the vehicle and check for proper clearance between the fan blade assembly and the fan shroud.

Scheme 67

An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L/4.7L gas powered engines have the block heater located to the rear on the right side of the engine.

Scheme 68

The 5.7L engine has the block heater (1) located on the left side of the engine below the exhaust manifold in the rear of the engine and is not immersed in engine coolant but makes direct contact with the block .

1. Raise vehicle.
2. Remove power cord from block heater (1).
3. Remove bolt (2) on block heater (1). Remove heater assembly (1).

Scheme 69

1. Disconnect the battery negative cables.
2. Drain coolant from radiator and cylinder block. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000).
3. Unscrew the power cord retaining cap and disconnect cord from heater element.
4. Using a suitable size socket, loosen and remove the block heater element. (Scheme 67)

1. Clean and inspect the block heater hole.
2. Install the new O-ring seal(s) to heater.
3. Insert the block heater (1) 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 «Standard Procedure»(ref-457792-S30781673372012030200000) .
6. Start and warm the engine.
7. Check the block heater for leaks.

1. Thoroughly clean cylinder block core hole and block heater seat.
2. Insert block heater assembly (1) into the block.
3. With block heater fully seated, tighten bolt (1) to 2 N.m (17 in. lbs.) torque.

1. Clean and inspect the threads in the cylinder block and heater element.
2. Coat heater element threads with Mopar® Thread Sealer with Teflon.
3. Screw block heater (1) into cylinder block and tighten to 75 N.m (55 ft. lbs.).
4. Connect block heater cord and tighten retaining cap.
5. Fill cooling system with recommended coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
6. Start and warm the engine.
7. Check block heater for leaks.

Scheme 70

A centrifugal water pump 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.

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.

Scheme 71

The 3.7L and 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. see scheme 98

WATER PUMP

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 - 3.7L/4.7L

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.

STANDARD PROCEDURE - COOLANT AIR EVACUATION

Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components.

Note. To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system.

Note. The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system.

Note. For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor).

1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps.
2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank.
3. Attach the adapter cone (2) to the vacuum gauge (1).
4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1).
5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly.
6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1).
7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum.
8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse.
9. Close the vacuum generator/venturi ball valve.
10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly.
11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated.
12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system.
13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2).
14. Open the suction hose's ball valve to begin refilling the cooling system.
15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached.
16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly.
17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank.
18. With heater control unit in the HEAT position, operate engine with container cap in place.
19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container.
20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period.
21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap.

3.7L/4.7L

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

Scheme 72

1. Disconnect the negative battery cable.
2. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
3. Remove fan/viscous fan drive assembly from water pump. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) or «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) . Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
4. If the water pump is being replaced, do not unbolt the fan blade assembly from the thermal viscous fan drive. 1 - AUTOMATIC TENSIONER 2 - WATER PUMP PULLEY
5. Remove the radiator fan. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) or «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) .
6. Remove accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
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 on the water pump at the timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
9. Remove the water pump and gasket. Discard gasket.

Scheme 73

1. Disconnect negative battery cable.
2. Remove the air intake assembly. Refer to «BODY, Air Cleaner , Removal , 5.7L»(ref-457797-S42752377112012030200000) .
3. Remove the resonator mounting bracket.
4. Remove cooling fan assembly. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) or «FAN, Cooling, Viscous , Removal»(ref-457792-S41329399382012030200000) .
5. Drain coolant into a clean container. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
6. Remove the upper radiator hose from the thermostat housing (1) and position aside.
7. Remove serpentine belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
8. Remove idler pulley (5).
9. Remove belt tensioner assembly (4). Refer to «TENSIONER, Belt , Removal»(ref-457792-S17039236212012030200000) .
10. Remove lower radiator hose from the water pump and position aside.
11. Remove the upper metal heater tube from the cylinder head.
12. Remove water pump mounting bolts (6) and remove pump (3).

Scheme 74

1. Disconnect battery negative cables.
2. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
3. Disconnect ambient air temp sensor electrical connector and mass airflow sensor electrical connector (if equipped).
4. Remove turbocharger inlet tube and air filter housing. Refer to «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
5. Remove generator assembly. Refer to «GENERATOR , Removal»(ref-457799-S36013499732012030200000) .
6. Remove the accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
7. Remove water pump mounting bolts (1).
8. Remove O-ring from water pump (2).
9. Remove water pump (2). Clean water pump sealing surface on cylinder block.

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

To ensure proper gasket sealing, surface preparation must be performed, especially with the use of aluminum engine components.

Never use the following to clean gasket surfaces

1. Metal scraper.
2. Abrasive pad or paper to clean cylinder block and head.
3. High speed power tool with an abrasive pad or a wire brush).
4. High speed power tool with 3M Roloc™ Bristle Disc (white or yellow).

Only use the following for cleaning gasket surfaces

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper.

1. Clean mating surfaces and install water pump (3). Tighten mounting bolts to 24 N.m (18 ft. lbs.).
2. Install upper metal heater tube.
3. Install belt tensioner assembly (4). Refer to «TENSIONER, Belt , Installation»(ref-457792-S09501515412012030200000) .
4. Install idler pulley (5).
5. Install the lower radiator hose.
6. Install serpentine belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
7. Install the resonator mounting bracket.
8. Install cooling fan assembly. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) or «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
9. Install the upper radiator hose to the thermostat housing (1).
10. Install the air intake assembly. Refer to «BODY, Air Cleaner , Installation , 5.7L»(ref-457797-S01216084882012030200000) .
11. Connect negative battery cable.
12. Evacuate air and refill cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
13. Check cooling system for leaks. Refer to «Diagnosis and Testing»(ref-457792-S26721215612012030200000) .

Scheme 75

1. Install new O-ring seal (1) in groove (2) on water pump (3). 1 - BOLT 2 - WATER PUMP
2. Install water pump (2) with the weep hole facing downward. Tighten mounting bolts (1) to 24 N.m (18 ft. lbs.) torque.
3. Install generator assembly. Refer to «GENERATOR , Installation»(ref-457799-S02313752592012030200000) .
4. Install accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
5. Install air box and tube assembly. Refer to «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
6. Install air filter housing. Refer to «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
7. Evacuate air and refill cooling system. Refer to «PUMP, Water , Standard Procedure»(ref-457792-S22139213142012030200000) .
8. Connect both battery cables.
9. Start and warm the engine. Check for leaks. Refer to «Diagnosis and Testing»(ref-457792-S26721215612012030200000) .

Scheme 76

The radiator (1) is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks.

This radiator (1) does not contain an internal transmission oil cooler.

RADIATOR

1. Position the radiator (3) into the engine compartment. Take care not to damage cooling fins or tubes on the radiator and oil coolers when installing.
2. Install the rubber insulators (1) to the lower radiator mounting features (alignment dowel and support bracket at the lower part of the radiator).
3. Install the two radiator upper mounting bolts (2). Tighten the bolts to 8 N.m (71 in. lbs.).
4. Install the electric cooling fan (3). Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) or «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
5. Install the fan shroud (1, 2) by engaging the fan shroud's (1, 2) lower retaining clips to the radiator/electric cooling fan (3).
6. Install the fan shroud to radiator lower center retaining clip.
7. Install the fan shroud (1, 2) mounting bolts (4). Tighten to 10 N.m (89 in. lbs.).
8. Install the fan shroud to radiator upper center retaining clip. NOTE: Make sure all retaining clips lock into place.
9. Connect the electric cooling fan (3) electrical connector.
10. Engage the two A/C compressor/transmission combination cooler mounting brackets (2) to the left side of the radiator (1).
11. Connect the transmission cooler lines to the transmission cooler. Refer to «COOLER, Transmission Oil , Installation»(ref-457792-S13626886762012030200000) .
12. Install the two bolts that secure the A/C condenser to the right side of the radiator. Tighten the bolts to 2.2 N.m (20 in. lbs.).
13. Install the bolt securing the transmission cooler line (1) to radiator (3) bracket (2). Tighten the bolt securely.
14. Install the coolant overflow/recovery bottle. Refer to «BOTTLE, Coolant Recovery , Installation»(ref-457792-S28272110072012030200000) .
15. Install the windshield washer reserve tank. Refer to «RESERVOIR, Windshield Washer , Installation»(ref-457801-S01579885432012030200000) .
16. Install the front grille. Refer to «GRILLE , Installation»(ref-457777-S17835290622012030200000) .
17. If equipped, install the viscous fan. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) or «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
18. Connect the upper radiator hose and install the clamp in it's proper position.
19. Install the upper radiator seal plastic rivets (2).
20. Install the upper radiator seal push pins (1).
21. Raise and secure the vehicle.
22. Install the lower center electric fan to radiator retaining clip.
23. Install the lower radiator clamp and hose.
24. Install the lower radiator seal.
25. Install battery negative cable.
26. Fill cooling system with coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
27. Check the system for any leaks. Refer to «Diagnosis and Testing»(ref-457792-S26721215612012030200000) .
28. Operate the engine until it reaches normal operating temperature. Check cooling system fluid levels.

1. Install the rubber insulators to the alignment dowels at the lower part of radiator.
2. Lower the radiator into position while guiding the two alignment dowels into the lower radiator support.
3. Raise the vehicle.
4. Position the power steering cooler on the radiator and tighten the nuts to 10 N.m (90 in. lbs.)
5. Lower the vehicle.
6. Install the two upper radiator mounting bolts. Tighten the bolts to 12 N.m (105 in. lbs.) torque.
7. If equipped, connect the transmission cooler lines to the transmission cooler. Inspect quick connect fittings for debris and install until an audible "click" is heard. Tug on lines to verify connection. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
8. Connect both radiator hoses and install hose clamps.
9. Install the cooling fan. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) or «FAN, Cooling, Viscous , Installation»(ref-457792-S33156171422012030200000) .
10. Position the coolant recovery tank hose into the clips located on the top of the radiator.
11. Install the air box and the turbocharger inlet hose. Refer to «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) . Tighten clamps to 4 N.m (35 in. lbs.).
12. Connect the mass airflow sensor electrical connector and ambient air temp sensor electrical connector (if equipped).
13. Install the upper radiator shroud (1).
14. If equipped, connect the negative battery cable to the auxiliary battery.
15. Connect the battery negative cable.
16. Position heater controls to full heat position.
17. Fill cooling system with coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
18. Operate the engine until it reaches normal operating temperature. Check the cooling system and automatic transmission (if equipped) for leaks.

Scheme 77

The Engine Coolant Temperature (ECT) sensor (2) is used to sense engine coolant temperature. The ECT sensor protrudes into an engine water jacket.

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.

3.7L ENGINE

1. Apply thread sealant to ECT sensor threads.
2. Install ECT sensor (3) to engine.
3. Tighten sensor to 11 N.m (8 ft. lbs.) torque.
4. Connect electrical connector to ECT sensor (3).
5. Replace any lost engine coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .

4.7L ENGINE

1. Apply thread sealant to ECT sensor threads.
2. Install ECT sensor (1) to engine.
3. Tighten ECT sensor to 11 N.m (8 ft. lbs.) torque.
4. Connect electrical connector to ECT sensor (1).
5. Replace any lost engine coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .

Note. Viscous fan, fan shroud and electric cooling fan removed for clarity.

1. Apply thread sealant to the engine coolant temperature (ECT) sensor (2) threads.
2. Install the ECT sensor (2) into engine.
3. Tighten the ECT sensor (2) to 11 N.m (8 ft. lbs.) torque.
4. Connect the electrical connector to the ECT sensor (2).
5. Fill the cooling system the proper level. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .

1. Install ETC sensor (2) to engine.
2. Tighten sensor (2) to 18 N.m (13 ft. lbs.) torque.
3. Connect the electrical connector to the ETC sensor (2).
4. Install heat shield.
5. Install the upper EGR tube. Refer to «TUBE, Exhaust Gas Recirculation (EGR), Crossover , Installation»(ref-457800-S16437621272012030200000) .
6. Install the engine trim cover.
7. Replace any lost engine coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .

Scheme 78

The 3.7L/4.7L/5.7L engines use a pellet-type thermostat that controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall temperature control.

Coolant leakage into the pellet container will cause the thermostat to fail in the open position. Thermostats very rarely stick. Do not attempt to free a thermostat with a prying device.

On the 3.7L/4.7L engine the thermostat is designed to block the flow of the coolant bypass journal by 50% instead of completely blocking the flow. This design controls coolant temperature more accurately. see scheme 138

The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation.

1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
3. Remove the radiator hose clamp and radiator hose (1) at the thermostat housing (3).
4. Remove the thermostat housing mounting bolts, thermostat housing (3) and thermostat .

Scheme 79

Note. Thermostats for the Cummins diesel, while physically interchangeable, should not be mixed and matched. For model year 2010 and forward, the 6.7L diesel engine uses a 200° Fahrenheit thermostat. Confirm the temperature stamp on the thermostat rim prior to removal or installation.

1. Disconnect the battery negative cables.
2. Remove the vent plug near EGR cooler.
3. Drain the cooling system until the coolant level is below the thermostat. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
4. Disconnect the exhaust gas pressure sensor electrical connector (3).
5. Remove the exhaust pressure tube (4) from the thermostat housing.
6. Remove the EGR cooler cross over tube (1).
7. Remove the radiator hose clamp and hose from the thermostat housing (1).
8. Remove the heat shield.
9. Remove the three water outlet-to-cylinder head bolts (5) and remove the water outlet connector.
10. Clean the mating surfaces of the thermostat housing (1) and clean the thermostat seat groove at the top of the thermostat housing (1).

1. Clean the mating areas of the timing chain cover (4) and the thermostat housing (1).
2. Install the thermostat (3) (spring side down) into the recessed machined groove on the timing chain cover (4). 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.
3. Position the thermostat housing (1) on the timing chain cover (4).
4. Install the housing-to-timing chain cover bolts. Tighten the bolts to 13 N.m (112 in. lbs.).
5. Install the lower radiator hose on the thermostat housing (1).
6. Install the splash shield.
7. Lower the vehicle.
8. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
9. Connect negative battery cable.
10. Start and warm the engine. Check for leaks.

1. Position the thermostat and thermostat housing (3) onto the water pump.
2. Install the thermostat housing (3) bolts. Tighten the bolts to 13 N.m (10 ft. lbs.).
3. Install the radiator hose (1) onto the thermostat housing (3).
4. Fill the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
5. Connect the negative battery cable.
6. Start and warm the engine. Check for leaks. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .

Note. Thermostats for the Cummins diesel, while physically interchangeable, should not be mixed and matched. For model year 2010 and forward, the 6.7L diesel engine uses a 200° Fahrenheit thermostat. Confirm the temperature stamp on the thermostat rim prior to removal or installation.

1. Inspect the thermostat seal for cuts or nicks. Replace if damaged.
2. Install the thermostat into the groove in the top of the cylinder head.
3. Install the thermostat housing and bolts (5). Tighten the bolts to 10 N.m (89 in. lbs.).
4. Install the heat shield. Tighten the bolts to 9 N.m (79 in. lbs.).
5. Install the exhaust pressure tube (4). Tighten to 10 N.m (89 in. lbs.).
6. Connect exhaust pressure sensor electrical connector (2).
7. Install the EGR cross over tube (1).
8. Install the P-clip and bolt. Tighten to 8 N.m (71 in. lbs.).
9. Install the radiator upper hose and clamp.
10. Fill the cooling system with coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
11. Connect the battery negative cables.
12. Start the engine and check for any coolant leaks. Run engine to check for proper thermostat operation.

Scheme 80

An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler. (Scheme 79)

GAS ENGINES

Transmission oil is routed through the cooler where heat is removed from the transmission oil before returning to the transmission.

Scheme 81

1. Place a drain pan under the oil cooler lines.
2. Disconnect the transmission oil cooler line quick-connect fitting at the cooler outlet. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) . Plug the cooler lines to prevent oil leakage.
3. Unsnap the transmission cooler tubes from the radiator tank clips.
4. Remove the bolt attaching the transmission cooler to the radiator.
5. Remove oil cooler from the vehicle. Take care not to damage the radiator core or transmission cooler tubes.

Scheme 82

1. Remove Charge Air Cooler. Refer to «COOLER and HOSES, Charge Air, Removal, 6.7L»(ref-457798-S06792333312012030200000).
2. Place a drain pan under the oil cooler.
3. Raise the vehicle.
4. Disconnect the oil cooler quick-connect fittings from the transmission lines. Refer to «TUBES AND HOSES, Transmission Oil Cooler, Standard Procedure»(ref-457792-S39844769592012030200000).
5. Remove the charge air cooler-to-oil cooler bolt. see scheme 147
6. Remove two mounting nuts.
7. Remove the oil cooler and line assembly towards the front of vehicle. Cooler must be rotated and tilted into position while removing.

Scheme 83

1. Disconnect both battery negative cables.
2. Remove starter. Refer to «STARTER , Removal»(ref-457802-S39254669482012030200000) .
3. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
4. Disconnect coolant lines from cooler. NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler.
5. Disconnect transmission oil lines from cooler. Plug cooler lines to prevent oil leakage.
6. Remove cooler bracket to transmission adapter bolt.
7. Remove the nut (6) secures the ground cable to the mounting stud then remove the nut.
8. Remove the upper nut (2).
9. Remove cooler bracket to block bolts (1).
10. Remove cooler assembly from vehicle.

Scheme 84

Note. The transmission oil cooler uses an internal thermostat to control transmission oil flow through the cooler. This thermostat is serviceable.

1. Remove the transmission oil cooler. Refer to «COOLER, Transmission Oil, Removal»(ref-457792-S23821098932012030200000).
2. Remove the snap ring (4) retaining the thermostat end plug (3). (Scheme 80)
3. Remove the end plug (3), thermostat (5) and spring (2) from transmission oil cooler. (Scheme 80)

1. Position the transmission cooler tubes to the front of the radiator by sliding brackets into slots on radiator inlet tank.
2. Snap the transmission cooler tubes into the clips on the side of the radiator tank.
3. Install the transmission cooler attaching bolt. Tighten the bolt to 16 N.m (140 in. lbs.).
4. Inspect the quick connect fittings for debris and install the quick connect fitting on the cooler tube until an audible "click" is heard. Pull on the connection to verify proper installation and install the secondary latches. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
5. Start the engine and check all fittings for leaks.
6. Check the fluid level in the automatic transmission.

AIR TO OIL COOLER - DIESEL

1. Carefully position the oil cooler assembly to the vehicle.
2. Install two nuts and one bolt. Tighten to 11 N.m (95 in. lbs.) torque.
3. Connect the quick-connect fittings to the transmission cooler lines. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
4. Install Charge Air Cooler. Refer to «COOLER and HOSES, Charge Air , Installation , 6.7L»(ref-457798-S10360382232012030200000) .
5. Start the engine and check all fittings for leaks.
6. Check the fluid level in the automatic transmission.

WATER-TO-OIL COOLER

1. Guide the oil cooler onto the studs located on the cylinder block.
2. Install the upper (2) and lower nuts to cylinder block finger tight.
3. Install and tighten mounting bolt (1) to cooler at cylinder block to 24 N.m (18 ft. lbs).
4. Torque the nuts to 24 N.m (18 ft. lbs.)
5. Install the ground cable. Install the retaining nut (6).
6. Tighten lower mounting bolt to cooler at the cylinder block. Tighten to 77 N.m (57 ft. lbs.). NOTE: Use a back-up wrench on the transmission cooler fittings to prevent damage to the cooler.
7. Tighten upper mounting bolt to cooler at cylinder block to 24 N.m (18 ft. lbs).
8. Install wire harness push in clip at bottom of cooler bracket.
9. Install starter motor. Refer to «STARTER , Installation»(ref-457802-S22328630612012030200000) .
10. Connect battery negative cables.
11. Fill cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
12. Check transmission oil level and fill as necessary.

Scheme 85

1. Remove dust cap by pulling it straight back off of quick connect fitting
2. Place disconnect Special Tool (special tool #8875A, Disconnect, Transmission Cooler Line) onto a half inch transmission cooler lines or Special Tool (special tool #9546, Disconnect Tool) onto a 1/2 inch transmission cooler lines with the fingers of the tool facing the quick connect fitting.
3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting.
4. Rotate the disconnect tool 60° to expand the retaining clip.
5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove.

Scheme 86

1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting.
2. Push in on transmission cooler line until a "click" is heard or felt.
3. Slide dust cap down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed.

Note. If dust cap will not snap into place, repeat assembly step 2.