JA COOLING SYSTEM 7-1

COOLING SYSTEM
CONTENTS

page page

GENERAL INFORMATION RADIATOR FAN CONTROL . . . . . . . . . . . . . . . . 17

ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 2 TEMPERATURE GAUGE INDICATION . . . . . . . . 19
AUTOMATIC TRANSMISSION OIL COOLERS . . . 5 TESTING SYSTEM FOR LEAKS . . . . . . . . . . . . 18
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WATER PUMP DIAGNOSIS . . . . . . . . . . . . . . . 16
COOLANT RECOVERY SYSTEM (CRS) . . . . . . . 2 SERVICE PROCEDURES
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2 COOLANT LEVEL CHECK—ROUTINE . . . . . . . 20
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . . 5 COOLANT LEVEL—SERVICING . . . . . . . . . . . . 20
COOLING SYSTEM PRESSURE CAP . . . . . . . . . 5 COOLANT—ADDING ADDITIONAL . . . . . . . . . 20
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 6 COOLING SYSTEM—DRAINING . . . . . . . . . . . . 21
ENGINE THERMOSTATS . . . . . . . . . . . . . . . . . . . 3 COOLING SYSTEM—REFILLING . . . . . . . . . . . 22
EXTERNAL TRANSMISSION OIL COOLER . . . . . 6 REMOVAL AND INSTALLATION
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ACCESSORY DRIVE BELTS—2.0/2.4L
WATER PIPES—2.5L . . . . . . . . . . . . . . . . . . . . . 2 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
WATER PUMP INLET TUBE—2.0/2.4L ACCESSORY DRIVE BELTS—2.5L ENGINE . . . 28
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 27
WATER PUMP—2.0/2.4L ENGINES . . . . . . . . . . 3 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
WATER PUMP—2.5L ENGINE . . . . . . . . . . . . . . 5 RADIATOR DRAINCOCK . . . . . . . . . . . . . . . . . . 26
DESCRIPTION AND OPERATION RADIATOR FAN, MOTOR AND SHROUD . . . . . 26
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . . 7 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COOLING SYSTEM PRESSURE CAP . . . . . . . . . 7 WATER PUMP INLET TUBE—2.0/2.4L
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 8 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
RADIATOR HOSES AND CLAMPS . . . . . . . . . . . 8 WATER PUMP—2.0/2.4L ENGINES . . . . . . . . . 22
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 WATER PUMP—2.5L ENGINE . . . . . . . . . . . . . 23
WATER PUMP—2.0/2.4L ENGINES . . . . . . . . . . 9 CLEANING AND INSPECTION
WATER PUMP—2.5L ENGINE . . . . . . . . . . . . . . 9 ACCESSORY DRIVE BELT INSPECTION . . . . . . 31
DIAGNOSIS AND TESTING CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . 32
ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . 19 CLEANING COOLING SYSTEM . . . . . . . . . . . . . 31
COOLANT CONCENTRATION TESTING . . . . . . . 18 COOLING SYSTEM CAP . . . . . . . . . . . . . . . . . . 31
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . 10 RADIATOR FLUSHING . . . . . . . . . . . . . . . . . . . 31
COOLING SYSTEM FLOW CHECK . . . . . . . . . . 16 REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . . 31
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 19 WATER PUMP—2.0/2.4L ENGINES . . . . . . . . . 30
ELECTRIC FAN MOTOR TEST . . . . . . . . . . . . . . 17 WATER PUMP—2.5L ENGINE . . . . . . . . . . . . . 30
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 20 ADJUSTMENTS
ENGINE THERMOSTAT TESTING . . . . . . . . . . . 16 BELT TENSION GAUGE METHOD . . . . . . . . . . . 32
LOW COOLANT LEVEL AERATION . . . . . . . . . . 19 SPECIFICATIONS
PRESSURE CAP TO FILLER NECK SEAL COOLING SYSTEM CAPACITY . . . . . . . . . . . . . 32
PRESSURE RELIEF CHECK . . . . . . . . . . . . . . 18 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PRESSURE TESTING COOLING SYSTEM SPECIAL TOOLS
PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . 19 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7-2 COOLING SYSTEM JA

GENERAL INFORMATION WATER PIPES—2.5L

The 2.5L engine use metal piping beyond the lower
COOLING SYSTEM radiator hose to route coolant to the suction side of
The cooling system consists of an engine cooling water pump, located in the V of the cylinder banks.
module, thermostat, coolant, a water pump to circu- The pipes are also provided with inlet nipples for
late the coolant. The engine cooling module may con- thermostat bypass, heater return coolant hoses, and
sist of a radiator, electric fan motor, shroud, radiator brackets for rigid engine attachment. The pipes
pressure cap, coolant reserve system, transmission employ O-rings for sealing at their interconnection
oil cooler and lines, hoses, clamps, and air condition- and to the water pump (Fig. 3).
ing condenser.
• When Engine is cold: Thermostat is closed, cool- ACCESSORY DRIVE BELTS
ing system has no flow through the radiator. The The engines are equipped with 2 accessory drive
coolant bypass flows through the engine and heater belts. One belt drives the power steering pump, the
core. other drives the generator and air conditioning (Fig.
• When Engine is warm: Thermostat is open, cool- 4) or (Fig. 5).
ing system has bypass flow and coolant flow through
radiator and heater core. COOLANT RECOVERY SYSTEM (CRS)
The primary purpose of a cooling system is to This system works in conjunction with the pres-
maintain engine temperature in a range that will sure cap to utilize thermal expansion and contraction
provide satisfactory engine performance and emission of the coolant to keep the coolant free of trapped air.
levels under all expected driving conditions. It also It provides a volume for expansion and contraction,
provides hot water (coolant) for heater performance provides a convenient and safe method for checking
and cooling for automatic transmission oil. It does coolant level, and adjusting level at atmospheric
this by transferring heat from engine metal to cool- pressure without removing the pressure cap. It also
ant, moving this heated coolant to the radiator, and provides some reserve coolant to cover minor leaks
then transferring this heat to the ambient air. and evaporation or boiling losses. All vehicles are
Coolant flow circuits for 2.0L and 2.4L engine equipped with this system (Fig. 6).
equipped vehicles are shown in (Fig. 1). The 2.5L See Coolant Level Check Service, Deaeration and
engine coolant flow circuit is shown in (Fig. 2). Pressure Cap sections for operation and service.

Fig. 1 Cooling System Operation—2.0L and 2.4L Engines

JA COOLING SYSTEM 7-3
GENERAL INFORMATION (Continued)

Fig. 2 Cooling System Operation—2.5L Engine

mostat housing/engine outlet connector (Fig. 7) and
(Fig. 8). The thermostat has a air bleed located in the
flange and a O-ring with a locating dimple incorpo-
rate on it. There is a relief in the cylinder head for
locating the air bleed.
The 2.5L engine thermostat is located in a thermo-
stat housing, located below the throttle body. This
thermostat has an air bleed valve, located in the
thermostat flange (Fig. 9).

Fig. 4 Drive Belts—2.0/2.4L Engine

WATER PUMP—2.0/2.4L ENGINES
Fig. 3 Engine Inlet Coolant Pipes—2.5L Engine The water pump body is made of aluminum with a
ENGINE THERMOSTATS steel impeller. The water pump is bolted to the front
The 2.0L and 2.4L engine thermostats are located of the block, and driven by the timing belt. The water
on the front of the engine (radiator side) in the ther- pump is the heart of the cooling system, pumping the
7-4 COOLING SYSTEM JA
GENERAL INFORMATION (Continued)
coolant through the engine block, cylinder head,
heater core, and radiator.

Fig. 7 Thermostat/Engine Outlet Connector—2.0L

Engine

Fig. 5 Drive Belts—2.5L Engine

Fig. 8 Thermostat and Engine Outlet Connector—

2.4L Engine

Fig. 6 Coolant Recovery System

NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
Fig. 9 Thermostat, Housing and Inlet Elbow—2.5L
Engine
JA COOLING SYSTEM 7-5
GENERAL INFORMATION (Continued)

WATER PUMP—2.5L ENGINE valve is stuck shut, the radiator hoses will col-
The 2.5L pump bolts directly to the engine block lapse on cool-down. Clean the vent valve (Fig.
uses a gasket for pump to block sealing (Fig. 10). The 11) to ensure proper sealing when boiling point
pump is serviced as an assembly. is reached.
The water pump is driven by the timing belt. See
Timing Belt in Group 9, Engine for component
removal providing access to water pump.

Fig. 11 Cooling System Pressure Cap to Filler Neck

There is a gasket in the cap that seals to the top of
the filler neck so that vacuum is maintained to draw
coolant back into the system from the coolant reserve
system tank.

RADIATOR
Fig. 10 Water Pump—2.5L Engine The radiators are cross flow types (horizontal
tubes) with design features that provide greater
WATER PUMP INLET TUBE—2.0/2.4L strength as well as sufficient heat transfer capabili-
ENGINES ties to keep the engine satisfactorily cooled (Fig. 12).
The inlet tube connects the water pump to the
radiator and heater core. This tube is sealed by an CAUTION: Plastic tanks, while stronger then brass
O-ring and held in place by fasteners to the block. are subject to damage by impact, such as
wrenches.
COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine block COOLING SYSTEM FANS
metal and in the cylinder head area near the exhaust All models use electric motor driven, two speed
valves. Then coolant carries this heat to the radiator cooling system fans. The fan modules include a motor
where the tube/fin assemblies of these components support and shroud. The module is fastened to the
can give off the heat to the air. radiator by bolts (Fig. 13).
Mopart Antifreeze or the equivalent is recom-
NOTE: Attempts to reduce high temperature gauge
mended for optimum cooling performance and corro-
reading by increasing engine speed, at the same
sion protection when mixed to a freeze point of -37° C
vehicle speed, can increase high engine coolant
(-35° F).
temperature.
COOLANT REPLACEMENT
Refer to Group 0, Lubrication and Maintenance for AUTOMATIC TRANSMISSION OIL COOLERS
schedule.
Oil coolers are internal oil to coolant type, mounted
in the radiator left tank (Fig. 14). Rubber oil lines
COOLING SYSTEM PRESSURE CAP feed the oil cooler and the automatic transmission.
The cooling system is equipped with a pressure cap Use only approved transmission oil cooler hose. Since
that releases pressure at some point within a range these hoses are molded to fit space available, replace-
of 97-124 kPa (14-18 psi) (Fig. 11). ment molded hoses are recommended. Tighten Oil
The system will operate at higher than atmo- Cooler Hose Clamps to 2 N·m (18 in. lbs.).
spheric pressure, which raises the coolant boiling
point, allowing increased radiator cooling capacity.
There is a vent valve in the center of the cap that
allows a small coolant flow to the CRS tank. If the
7-6 COOLING SYSTEM JA
GENERAL INFORMATION (Continued)

Fig. 12 Radiator Module

Fig. 13 Fan Module

EXTERNAL TRANSMISSION OIL COOLER
An external oil-to-air type transmission oil cooler is
mounted ahead of the cooling module (Fig. 15) and
(Fig. 16). This style of cooler uses steel tubes and Fig. 14 Transmission Oil Cooler
rubber oil lines to feed oil from the internal (in radi-
ator tank) cooler to the external cooler and then to Refer to Description and Operation in this section for
the automatic transmission. Use only approved more information.
transmission oil cooler hose. Since these hoses are
molded to fit space available, replacement molded DESCRIPTION AND OPERATION
hoses are recommended.
THERMOSTAT
ENGINE BLOCK HEATER The engine cooling thermostats are wax pellet
On all models an engine block heater is available driven, reverse poppet choke type. They are designed
as an optional accessory. The heater, operated by to provide the fastest warm up possible by prevent-
ordinary house current (110 Volt A.C.) through a ing leakage through them and to guarantee a mini-
power cord and connector behind the radiator grille. mum engine operating temperature of 88 to 93°C
JA COOLING SYSTEM 7-7
DESCRIPTION AND OPERATION (Continued)
(192 to 199°F). They also automatically reach wide COOLANT PERFORMANCE
open so they do not restrict flow to the radiator as Performance is measurable. For heat transfer, one
temperature of the coolant rises in hot weather to pound of pure water absorbs 1 btu for each degree of
around 104°C (220°F). Above this temperature the temperature rise. This formula is altered when nec-
coolant temperature is controlled by the radiator, fan, essary additives to control boiling, freezing, and cor-
and ambient temperature, not the thermostat. rosion are added as follows:
• Pure Water (1 btu) boils at 100°C (212°F) and
freezes at 0°C (32°F).
• 100 Percent ethylene glycol (.7 btu) can cause an
engine to run hot, cause detonation, and will freeze
at -22°C (-8°F).
• 50/50 Ethylene Glycol and Distilled Water (.82
btu) is the recommended combination that provides a
freeze point of -37°C (-35°F). The radiator, water
pump, engine water jacket, radiator pressure cap,
thermostat, temperature gauge, coolant sensor and
heater are all designed for 50/50 ethylene glycol.
Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of -46°C
(-50°F).

NOTE: Richer mixtures cannot be measured with

field equipment and can lead to problems associ-
Fig. 15 Transmission Oil Cooler—2.0/2.4L Engines ated with 100 percent glycol. If there is doubt that
the coolant mixture is to rich for field equipment to
measure, put a sample in a clean container. Add
exactly the same amount of water and retest. If the
coolant in the vehicle is 100% antifreeze, the diluted
sample will read 50% . If the coolant in the vehicle
was 70% antifreeze and 30% water, the diluted sam-
ple will read as 35% , etc.

SELECTION AND ADDITIVES

The use of aluminum cylinder heads, intake mani-
folds, and water pumps requires special corrosion
protection. Mopart Antifreeze or the equivalent is
recommended for optimum engine cooling and protec-
tion against corrosion when mixed to a freeze point of
-37°C (-35°F) to -59°C (-50°F). If it looses color or
becomes contaminated; drain, flush, and replace with
fresh properly mixed solution.

CAUTION: Do not use well water, or suspect water

supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended.
Fig. 16 Transmission Oil Cooler—2.5L Engine
The thermostat is operated by a wax filled con- COOLING SYSTEM PRESSURE CAP
tainer (pellet) which is sealed. When heated coolant The cooling system is equipped with a pressure cap
reaches a predetermined temperature, the wax that releases built up pressure, maintaining a range
expands enough to overcome the closing spring and of 97-124 kPa (14-18 psi).
water pump pressure, which forces the valve to open. The cooling system will operate at higher than
Coolant leakage into the wax pellet will cause a atmospheric pressure. The higher pressure raises the
thermostat to fail open. Do not attempt to free-up a coolant boiling point thus, allowing increased radia-
stuck open thermostat. tor cooling capacity.
7-8 COOLING SYSTEM JA
DESCRIPTION AND OPERATION (Continued)
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting allowing coolant to return to radiator
from coolant reserve system tank by vacuum through
connecting hose. If valve is stuck shut, the radia-
tor hoses will be collapsed on cool down. Clean
the vent valve (Fig. 17) to ensure proper sealing
when boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.

Fig. 18 Spring Clamp Size Location

Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended.
Fig. 17 Cooling System Pressure Cap Make sure hoses and connectors are clean and dry
RADIATOR HOSES AND CLAMPS before installation. Do not lubricate hoses when
installing.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, Spring type hose clamps are used in all applica-
WAIT 15 MINUTES BEFORE WORKING ON VEHI- tions. If replacement is necessary, replace with the
CLE. RELIEVE PRESSURE BY PLACING A SHOP original Mopart equipment spring type clamp.
TOWEL OVER THE CAP AND WITHOUT PUSHING
DOWN ROTATE IT COUNTERCLOCKWISE TO THE
FIRST STOP. ALLOW FLUIDS TO ESCAPE
THROUGH THE OVERFLOW TUBE AND WHEN THE
SYSTEM STOPS PUSHING OUT COOLANT AND
STEAM AND THE PRESSURE DROPS CONTINUE
SERVICE.

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
Fig. 19 Hose Clamp Tool
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
ENGINE BLOCK HEATER
The heater, operated by ordinary house current
is necessary, use only a original equipment clamp
(110 Volt A.C.) through a power cord and connector
with matching number or letter (Fig. 18).
behind the radiator grille, provides easier engine
The hose clamps are removed by using Special Tool starting and faster warm-up when vehicle is operated
6094 or equivalent constant tension clamp pliers in areas having extremely low temperatures. The
(Fig. 19) to compress hose clamp. heater is mounted in a core hole (in place of a core
A hardened, cracked, swollen or restricted hose hole plug) in the engine block, with the heating ele-
should be replaced. Do not damage radiator inlet and ment immersed in coolant (Fig. 20). The power
outlet when loosening hoses. cord must be secured in its retainer clips, and
not positioned so it could contact linkages or
JA COOLING SYSTEM 7-9
DESCRIPTION AND OPERATION (Continued)

Fig. 20 Engine Block Heater

exhaust manifolds and become damaged. For inder block. The water pump inlet is located at the
removal procedures, refer to Removal and rear of the pump, a inlet tube located between the
Installation in this section. cylinder heads connects the water pump with the
thermostat housing (Fig. 22). The water pump is
WATER PUMP—2.0/2.4L ENGINES driven by the timing belt. Refer to Group 9, Engine
The water has a diecast aluminum body and hous- for timing belt removal.
ing with a stamped steel impeller. The water pump
bolts directly to the block (Fig. 21). Cylinder block to NOTE: The water pump can be replaced with out
water pump sealing is provided by a rubber O-ring. discharging the air conditioning system.
The water pump is driven by the timing belt. Refer
to Group 9, Engine section for component removal to
access the water pump.

NOTE: The water pump on all models can be

replaced without discharging the air conditioning
system.

Fig. 22 Water Pump and Inlet Tube

Fig. 21 Water Pump

WATER PUMP—2.5L ENGINE
The water pump has a aluminum body with a steel
impeller. A gasket is used to seal the pump to the cyl-
7 - 10 COOLING SYSTEM JA

DIAGNOSIS AND TESTING

COOLING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSE CORRECTION

TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On Board Diagnostic in
LOW (DTC) been set indicating a stuck Group 25. Replace thermostat, if
open engine thermostat? necessary. If a (DTC) has not been
set, the problem may be with the
temperature gauge.
2. Is the temperature gauge (if 2. Check the connector at the
equipped) connected to the engine coolant sensor. Refer to
temperature gauge coolant sensor Group 8E. Repair as necessary.
on the engine?
3. Is the temperature gauge (if 3. Check Gauge operation. Refer to
equipped) operating OK? Group 8E. Repair as necessary.
4. Coolant level low during cold 4. Check coolant level in the coolant
ambient temperature, accompanied recovery/reserve container and the
by poor heater performance. radiator. Inspect the system for
leaks. Repair as necessary. Refer to
WARNINGS in this section before
removing pressure cap.

TEMPERATURE GAUGE READS 1. Trailer being towed, a steep hill 1. This may be a temporary
HIGH OR ENGINE COOLANT being climbed, vehicle being condition and repair is not
WARNING LAMP ILLUMINATES. operated in slow moving traffic, or necessary. Turn off the air
COOLANT MAY OR MAY NOT BE engine idling during high ambient conditioning and drive the vehicle
LOST FROM SYSTEM. (outside) temperatures with air without any of the previous
conditioning on. High altitudes conditions. Observe the temperature
Could aggravate these conditions. gauge the gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause of the
overheating and repair. Refer to
POSSIBLE CAUSES in this section.
2. Is temperature gauge (if 2. Check gauge. Refer to Group 8E.
equipped) reading correctly? Repair as necessary.
3. Is temperature warning lamp (if 3. Check warning lamp operation.
equipped) illuminating Refer to Group 8E. Repair as
unnecessarily? necessary.
4. Coolant low in recovery/reserve 4. Check for coolant leaks and
container and radiator? repair as necessary. Refer to
Checking Cooling System for Leaks
in this section.
5. Pressure cap not installed tightly. 5. Tighten cap.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.
JA COOLING SYSTEM 7 - 11
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

6. Poor seals at radiator cap. 6. (a) Check condition of cap and

cap seals. Refer to Radiator cap
Inspection. Replace cap if
necessary.
(b) Check condition of filler neck . If
neck is bent or damaged, replace
neck.
7. Coolant level low in radiator, but 7. (a) Check condition of radiator
not in coolant recovery/reserve cap and cap seals. Replace cap if
container. This indicates the necessary.
radiator is not drawing coolant from (b) Check condition of filler neck.
the coolant recovery/reserve Replace if damaged.
container as the engine cools. As
(c) Check condition of hose from
the engine cools, a vacuum is
filler neck to coolant container. It
formed inside the cooling system. If
should be tight at both ends without
the radiator cap seals are defective,
any kinks or tears. Replace hose as
or the cooling system has a leak, a
necessary.
vacuum cannot be formed.
(d) Check coolant recovery/reserve
container and hose for blockage.
Repair as necessary.
8. Freeze point of coolant not 8. Check coolant concentration.
correct. Mixture ratio may be too Refer to Coolant Concentration
rich. Testing in this section. Adjust
glycol-to-water ration as required.
9. Coolant not flowing through 9. Check for coolant flow at filler
system. neck with some coolant removed,
engine warm, and thermostat open.
Coolant should be observed flowing
through filler neck. If flow is not
observed, determine reason for lack
of flow and repair as necessary.
10. Radiator or A/C condenser fins 10. Clean obstruction from fins.
are dirty or clogged.
11. Radiator core is plugged or 11. Replace or re-core radiator.
corroded.
12. Fuel or ignition system 12. Refer to Fuel and Ignition
problems. System groups for diagnosis. Also
refer to the appropriate Powertrain
Diagnostic Procedure manual.
13. Dragging Brakes. 13. Inspect brake system and repair
as necessary. Refer to Group 5,
Brakes for diagnosis.
14 Bug screen or other aftermarket 14. Remove bug screen or
accessory is being used causing accessory.
reduced air flow.
15. Thermostat partially or 15. Check thermostat operation and
completely closed. This is more replace as necessary. Refer to
prevalent on high mileage vehicles. thermostat in this section for
procedure.
7 - 12 COOLING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

16. Electric cooling fan not 16. Check electric fan operation and
operating properly. repair as necessary.
17. Cylinder head gasket leaking. 17. Check cylinder head gasket for
leaks. Refer to testing cooling
system for leaks. For repairs, refer
to Group 9, Engine.
18. Heater core leaking. 18. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning and repair as
necessary.

TEMPERATURE GAUGE READING 1. The gauge may cycle up and 1. A normal condition. No correction
IS INCONSISTENT (FLUCTUATES, down. This is due to the cycling of is necessary. If gauge cycling is
CYCLES OR IS ERRATIC) the electric radiator fan. going into the hot zone, check
electric fan operation and repair as
necessary. Refer to procedure in
this section.
2. During cold weather operation 2. A normal condition. No correction
with the heater blower in the high is necessary.
position, the gauge reading may
drop slightly.
3. Temperature gauge or engine 3. Check operation of gauge and
mounted gauge sensor is defective repair as necessary. Refer to Group
or shorted. 8E, Instrument Panel and Gauges.
4. Gauge reading rises when 4. A normal condition. No correction
vehicle is brought to a stop after is necessary. The gauge should
heavy use (engine still running). return to normal range after vehicle
is driven.
5. Gauge reading high after 5. A normal condition. No correction
restarting a warmed-up (hot) is necessary. The gauge should
engine. return to normal range after a few
minutes of engine operation.
6. Coolant level low in radiator (air 6. Check and correct coolant leaks.
will build up in the cooling system Refer to Testing Cooling System For
causing the thermostat to open Leaks in the section.
late).
7. Cylinder head gasket leaking 7. (a) Check for cylinder head
allowing exhaust gas to enter gasket leaks with a commercially
cooling system. This will cause available Block Leak Tester. Repair
thermostat to open late. as necessary.
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from exhaust system. Repair as
necessary.
8. Water pump impeller loose on 8. Check water pump and replace
shaft. as necessary. Refer to Water Pump
in this section.
9. Loose drive belt (water pump 9. Check drive belt and correct as
slipping). necessary.
JA COOLING SYSTEM 7 - 13
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

10. Air leak on the suction side of 10. Locate leak and repair as
water pump allows air to build up in necessary.
cooling system. This will cause the
thermostat to open late.

PRESSURE CAP IS BLOWING 1. Pressure relief valve in radiator 1. Check condition of radiator cap
OFF STEAM AND/OR COOLANT cap is defective. and seals. Refer to Radiator Cap in
FLOWING INTO RECOVERY this section. Replace as necessary.
CONTAINER. TEMPERATURE
GAUGE READING MAY BE ABOVE
NORMAL, BUT NOT HIGH.
COOLANT LEVEL MAY BE HIGH
IN RECOVERY CONTAINER.

COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT PRESSURE system hoses, water pump or necessary. Refer to Testing Cooling
CAP BLOWOFF. GAUGE IS engine. System For Leaks in this section.
READING HIGH OR HOT.

DETONATION OR PRE-IGNITION 1. Engine overheating. 1. Check reason for overheating

(NOT CAUSED BY IGNITION and repair as necessary.
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH. 2. Freeze point of coolant not 2. Check the freeze point of the
correct. coolant. Refer to Coolant
Concentration Testing in this
section. Adjust glycol-to-water ratio
as required.

HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. (a) Radiator cap relief valve
WHEN ENGINE IS COOLING system on engine cool-down is not stuck. Refer to Radiator Cap in this
being relieved through coolant section. Replace as necessary.
recovery/reserve container system.
(b) Hose between coolant
recovery/reserve container and
radiator is kinked. Repair as
necessary.
(c) Vent at coolant recovery/reserve
container is plugged. Clean vent
and repair as necessary.
(d) Recovery/reserve container is
internally blocked or plugged. Check
for blockage and repair as
necessary.

ELECTRIC RADIATOR FAN 1. Fan relay, powertrain control 1. Refer to appropriate Powertrain
OPERATES ALL THE TIME. module (PCM) or engine coolant Diagnostic Procedures manual for
temperature sensor defective. operation of the DRB scan tool.
Repair as necessary.

2. Check for low coolant level. 2. Repair as necessary.

7 - 14 COOLING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

ELECTRIC RADIATOR FAN WILL 1. Fan motor defective. 1. Refer to appropriate Powertrain
NOT OPERATE. GAUGE READING Diagnostic Procedures manual for
HIGH OR HOT operation of the DRB scan tool.
Repair as necessary.

2. Fan relay, powertrain control 2. Refer to appropriate Powertrain

module (PCM) or engine coolant Diagnostic Procedures manual for
temperature sensor defective. operation of the DRB scan tool.
Repair as necessary.
3. Blown fuse in power distribution 3. Determine reason for blown fuse
center (PDC). and repair as necessary.

NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly.

Refer to Cooling System Fans in
this section.

2. Fan blades striking a surrounding 2. Locate point of fan blade contact

object. and repair as necessary.
3. Air obstructions at radiator or A/C 3. Remove obstructions and/or
condenser. clean debris from radiator and/or
A/C condenser.
4. Electric fan motor defective. 4. Refer to procedure in this section.

INADEQUATE AIR CONDITIONER 1. Radiator and/or air conditioning 1. Remove restriction and/or clean
PERFORMANCE (COOLING condenser is restricted, obstructed as necessary.
SYSTEM SUSPECTED) or dirty.

2. Electric radiator fan not operating 2. Refer to appropriate Powertrain

when A/C is on. Diagnostic Procedures manual for
operation of the DRB scan tool.
Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition.
be transferred from radiator to A/C Refer to this section.
condenser). High underhood
temperature due to engine
overheating may also transfer heat
to A/C components.
JA COOLING SYSTEM 7 - 15
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

INADEQUATE HEATER 1. Has a diagnostic trouble code 1. Refer to On-Board Diagnostic in

PERFORMANCE. (DTC) been set? Group 25, Emission Control
Systems.

2. Coolant level low. 2. Refer to testing cooling system

for leaks in this section. Repair as
necessary.
3. Obstructions in heater hose 3. Remove heater hoses at both
fittings at engine. ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping 5. Refer to water pump in this
coolant to heater core. When the section. Repair as necessary.
engine is fully warmed up, both
heater hoses should be hot to the
touch. The water pump drive belt
may be slipping causing poor water
pump operation.

HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and
certain driveline components. One replace or repair as necessary.
or more of these shields may be
missing.

2. Is temperature gauge reading 2. Refer to the previous

above the normal range? Temperature Gauge Reads High in
these Diagnostic Charts. Repair as
necessary.
3. Is cooling fan operating 3. Refer to Cooling System Fan in
correctly? this section for diagnosis. Repair as
necessary.
4. Has undercoating been applied 4. Clean undercoating as necessary.
to any unnecessary component.
5. Engine may be running rich 5. Refer to appropriate Powertrain
causing the catalytic converter to Diagnostic Procedures manual for
overheat. operation of the DRB scan tool.
Repair as necessary.

POOR DRIVEABILITY 1. For proper driveability, good 1. Refer to On-Board Diagnostics in

(THERMOSTAT POSSIBLY STUCK vehicle emissions and for Group 25, Emission Control
OPEN). GAUGE MAY BE READING preventing build-up of engine oil Systems. DTC’s may also be check
LOW sludge, the thermostat must be using the DRB scan tool. Refer to
operating properly. Has a diagnostic the proper Powertrain Diagnostic
trouble code (DTC ) been set? Procedure manual for checking the
thermostat if necessary.
7 - 16 COOLING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

STEAM IS COMING FROM FRONT 1. During wet weather, moisture 1. Occasional steam emitting from
OF VEHICLE NEAR GRILL AREA (snow, ice or rain condensation) on this area is normal. No repair is
WHEN WEATHER IS WET, the radiator will evaporate when the necessary.
ENGINE IS WARMED UP, thermostat opens. This opening
RUNNING, AND VEHICLE IS allows heated water into the
STATIONARY. TEMPERATURE radiator. When the moisture contact
GAUGE IS IN NORMAL RANGE. the hot radiator, steam may be
emitted. This usually occurs in cold
weather with no fan or airflow to
blow it away.

COOLANT COLOR 1. Coolant color is not necessarily 1. Check the freeze point of the
an indication of adequate corrosion coolant. Refer to Coolant
or temperature protection. Do not Concentration in the section for
rely on coolant color for determining procedure. Adjust the glycol-to-water
condition of coolant. ratio as required.

COOLANT LEVEL CHANGES IN 1. Level changes are to be 1. A normal condition. No repair is

COOLANT RECOVERY/RESERVE expected as coolant volume necessary.
CONTAINER fluctuates with engine temperature.
If the level in the container was
between the FULL and ADD marks
at normal engine operating
temperature, the level should return
to within that range after operation
at elevated temperatures.

ENGINE THERMOSTAT TESTING Another flow test to help determine pump opera-
The thermostat is operated by a wax filled con- tion, remove radiator cap.
tainer (pellet) which is sealed. When heated coolant
WARNING: DO NOT remove radiator cap if the cool-
reaches a predetermined temperature the wax pellet
ing system is hot or under pressure.
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Coolant leakage into the pellet will cause a thermo-
COOLING SYSTEM FLOW CHECK
stat to fail open. Do not attempt to free up a thermo-
To determine whether coolant is flowing through
stat with a screwdriver.
the cooling system, use the following procedures:
The thermostat that opens too soon type failure
(1) If engine is cold, idle engine until normal oper-
mode is included in the on-board diagnosis. The
ating temperature is reached. Then feel the upper
check engine light will not be lit by an open too soon
radiator hose. If it is hot, coolant is circulating.
condition. If it has failed open, a diagnostic trouble
code (DTC) will be set. Do not change a thermostat WARNING: DO NOT REMOVE THE COOLING SYS-
for lack of heater performance or temperature gauge TEM PRESSURE CAP WITH THE SYSTEM HOT AND
position, unless a DTC is present. See Diagnosis for UNDER PRESSURE BECAUSE SERIOUS BURNS
other probable causes. Thermostat failing shut is the FROM COOLANT CAN OCCUR.
normal long term mode of failure, and normally, only
on high mileage vehicles. The temperature gauge will (2) Remove pressure cap when engine is cold,
indicate this. Refer to Diagnosis in this section. remove small amount of coolant Idle engine until
thermostat opens, you should observe coolant flow
WATER PUMP DIAGNOSIS while looking down the filler neck. Once flow is
A quick flow test to tell whether or not the pump is detected install the pressure cap.
working is to see if the heater warms properly. A
defective pump will not be able to circulate heated
coolant through the long heater hose.
JA COOLING SYSTEM 7 - 17
DIAGNOSIS AND TESTING (Continued)

RADIATOR FAN CONTROL RADIATOR FAN OPERATION—2.4L ENGINE

Fan control is accomplished three ways. The fan
runs when the air conditioning pressure reaches a Radiator Fan Control A/C Pressure
set psi see charts below. In addition to this control, A/C Off Low High
the fan is turned on by the temperature of the cool-
ant which is sensed by the coolant temperature sen- Fan On: 104°C 110°C
sor which sends the message to the Powertrain (219°F) (230°F)
Control Module (PCM). The PCM turns on the fan Fan Off: 99°C 105°C
through a fan relay. On models equipped with auto- (210°F) (221°F)
matic transmission, a transmission fluid thermister A/C On Low High Low High
may have some influences on fan operation. See Wir-
Fan On: 99°C 110°C 1,448 1,718
ing Diagrams Manual for circuity and diagnostics
(210°F) (230°F) Kpa Kpa
provided.
(210 (249 psi)
The Powertrain Control Module (PCM) provides
psi)
fan control for the following conditions:
• The fan will not run during cranking until the Fan Off: 93°C 105°C 1,207 1,585
engine starts no matter what the coolant tempera- (199°F) (221°F) Kpa Kpa
ture is. (175 (229
• Fan will run when the air conditioning clutch is Psi) Psi)
engaged, low pressure cutout switch is closed and EATX Fluid Temperature Low High
once set compressor head pressure is reached. See Speed Speed
charts. Fan On: 118°C 122°C
• Fan will run according to the following informa- (244°F) (252°F)
tion charts.
Fan Off: 116°C 118°C
RADIATOR FAN OPERATION—2.0L ENGINE (240°F) (244°F)

Radiator Fan Control A/C Pressure

RADIATOR FAN OPERATION—2.5L ENGINE
A/C Off Low High
Fan On: 104°C 110°C
Radiator Fan Control A/C Pressure
(220°F) (230°F)
A/C Off Low High
Fan Off: 99°C 104°C
(210°F) (220°F) Fan On: 104°C 110°C
(220°F) (230°F)
A/C On Low High Low High
Fan Off: 98°C 105°C
Fan On: 99°C 110°C 1,466 1,717
(208°F) (221°F)
(210°F) (230°F) Kpa Kpa
(209 (249 psi) A/C On Low High Low High
psi) Fan On: 99°C 110°C 1,448 1,718
Fan Off: 93°C 104°C 1,172 1,579 (210°F) (230°F) Kpa Kpa
(200°F) (220°F) Kpa Kpa (210 (249 psi)
(170 (229 psi) psi)
psi) Fan Off: 93°C 105°C 1,207 1,585
EATX Fluid Temperature Low High (199°F) (221°F) Kpa kpa (229
Speed Speed (175 psi)
psi)
Fan On: 116°C 120°C
(240°F) (248°F) EATX Fluid Temperature Low High
Speed Speed
Fan Off: 109°C 116°C
(228°F) (240°F) Fan On: 118°C 122°C
(244°F) (252°F)
Fan Off: 116°C 118°C
ELECTRIC FAN MOTOR TEST (240°F) (244°F)
Refer to Powertrain Diagnostic Manual for proce-
dure.
7 - 18 COOLING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)
For wiring diagrams of the fan motor systems refer
to Group, 8W Wiring Diagrams.

COOLANT CONCENTRATION TESTING

Coolant concentration should be checked when any
additional coolant was added to system or after a
coolant drain, flush and refill. The coolant mixture
offers optimum engine cooling and protection against
corrosion when mixed to a freeze point of -37°C
(-34°F) to -59°C (-50°F). The use of a hydrometer or a
refractometer can be used to test coolant concentra-
tion.
Hydrometers test the amount of glycol in a mixture
by measuring the specific gravity of the mixture. The
higher the concentration of ethylene glycol, the larger
the number of balls that will float, and higher the Fig. 23 Pressure Testing Cooling System—Typical
freeze protection (up to a maximum of 70% by vol-
perature in order to open the thermostat and allow
ume glycol).
the coolant to expand. Reattach the tester. If the nee-
Refractometers test the amount of glycol in a cool-
dle on the dial fluctuates, it indicates a combustion
ant mixture by measuring the amount a beam of
leak and is usually a head gasket leak.
light bends as it passes through the fluid.
Some coolant manufactures use other types of gly- WARNING: WITH TOOL IN PLACE PRESSURE
cols into their coolant formulations. Propylene glycol BUILDS UP FAST. ANY EXCESSIVE AMOUNT OF
is the most common new coolant. However, propylene PRESSURE BUILT UP BY CONTINUOUS ENGINE
glycol based coolants do not provide the same freez- OPERATION MUST BE RELEASED TO A SAFE
ing protection and corrosion protection and is only PRESSURE POINT. NEVER PERMIT PRESSURE TO
recommended for limited usage. Refer to appropriate EXCEED 138 kPa (20 psi).
Technical Service Bulletin(s) regarding use of propy-
lene glycol based coolants. If the needle on the dial does not fluctuate, race
the engine a few times. If an abnormal amount of
CAUTION: Do not mix types of coolant—corrosion coolant or steam is emitted from the tailpipe, it may
protection will be severely reduced. indicate a faulty head gasket, cracked engine block or
cylinder head.
Because ethylene glycol and propylene glycol do
There may be internal leaks which can be deter-
not have the same specific gravities, the use of a
mined by removing the oil dipstick. If water globules
hydrometer will be inaccurate. Therefore, Special
appear intermixed with the oil, it will indicate a
Tool 8286 refractometer, must be used when testing
internal leak in the engine. If there is an internal
coolant.
leak, the engine must be disassembled for repair.
NOTE: A refractometer should be used if the glycol
type is unknown, and to achieve an accurate read- PRESSURE CAP TO FILLER NECK SEAL
ing of freeze protection. PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure relief can
be checked by removing the overflow hose at the radiator
TESTING SYSTEM FOR LEAKS filler neck nipple (Fig. 24). Attach the radiator pressure
With engine not running, wipe the coolant filler tester to the filler neck nipple, and pump air into the
neck sealing seat clean. The radiator should be full. system. The pressure cap upper gasket should relieve
Attach a radiator pressure tester to the coolant pressure at 69-124 kPa (10-18 psi), and hold pressure
filler neck, as shown in (Fig. 23) and apply 104 kPa at 55 kPa (8 psi) minimum.
(15 psi) pressure. If the pressure drops more than 2
psi in 2 minutes inspect all points for external leaks. WARNING: THE WARNING WORDS DO NOT OPEN
All hoses, radiator and heater, should be moved HOT ON THE PRESSURE CAP IS A SAFETY PRE-
while at 104 kPa (15 psi) since some leaks occur CAUTION. WHEN HOT, THE COOLING SYSTEM
while driving due to engine rock, etc. BUILDS UP PRESSURE. TO PREVENT SCALDING
If there are no external leaks after the gauge dial OR OTHER INJURY, THE PRESSURE CAP SHOULD
shows a drop in pressure, detach the tester. Start NOT BE REMOVED WHILE THE SYSTEM IS HOT
engine and run the engine to normal operating tem- AND/OR UNDER PRESSURE.
JA COOLING SYSTEM 7 - 19
DIAGNOSIS AND TESTING (Continued)
ket for irregularities that may prevent the cap from
sealing properly.

Fig. 24 Cooling System Pressure Cap to Filler Neck

There is no need to remove the pressure cap at any
time except for the following purposes:
• Check and adjust coolant freeze point
• Refill system with new coolant
• Conducting service procedures Fig. 25 Pressure Testing Radiator Cap
• Checking for leaks
LOW COOLANT LEVEL AERATION
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, Low coolant level in a cross flow radiator will
WAIT 15 MINUTES BEFORE REMOVING CAP. equalize in both tanks with engine off. With engine
PLACE A SHOP TOWEL OVER THE CAP, AND WITH- at running operating temperature the high pressure
OUT PUSHING DOWN, ROTATE IT COUNTER- inlet tank runs full and the low pressure outlet tank
CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS drops. If this level drops below the top of the trans-
TO ESCAPE THROUGH THE OVERFLOW TUBE. mission oil cooler, air will be sucked into the water
WHEN THE SYSTEM STOPS PUSHING COOLANT pump:
AND STEAM INTO THE CRS TANK AND PRESSURE • Transmission oil will become hotter.
DROPS, PUSH DOWN ON THE CAP AND REMOVE • High reading shown on the temperature gauge.
IT COMPLETELY. SQUEEZING THE RADIATOR • Air in the coolant will also cause loss of flow
INLET HOSE WITH A SHOP TOWEL (TO CHECK through the heater.
PRESSURE) BEFORE AND AFTER TURNING TO • Exhaust gas leaks into the coolant can also
THE FIRST STOP IS RECOMMENDED. cause the same problems.

DEAERATION
PRESSURE TESTING COOLING SYSTEM Air can only be removed from the system by gath-
PRESSURE CAP ering under the pressure cap. On the next heat up it
Dip the pressure cap in water; clean off any depos- will be pushed past the pressure cap into the CRS
its on the vent valve or its seat, and apply the cap to tank by thermal expansion of the coolant. It then
end of radiator pressure tester (Fig. 25). Working the escapes to the atmosphere in the CRS tank and is
plunger, increase the pressure to 104 kPa (15 psi) on replaced with solid coolant on cool down.
the gauge. If the pressure cap fails to hold pressure
of at least 97 kPa (14 psi), replace the cap. TEMPERATURE GAUGE INDICATION
At idle the temperature gauge could rise slowly to
CAUTION: The radiator pressure tester is very sen- about 1/2 gauge travel. The fan will come on and the
sitive to small air leaks that will not cause cooling gauge could drop to about 1/3 gauge travel, this is
system problems. A pressure cap that does not normal.
have a history of coolant loss should not be
replaced just because it leaks slowly when tested ACCESSORY DRIVE BELTS
with this tool. Add water to the tool. Turn the tool Satisfactory performance of the belt driven accesso-
upside down, and recheck the pressure cap to con- ries depends on belt condition and proper belt ten-
firm that the cap is faulty. sion.
If the pressure cap tests properly while posi-
tioned the on radiator pressure tester, but will not
hold pressure or vacuum when positioned on the
filler neck, inspect the filler neck and cap top gas-
7 - 20 COOLING SYSTEM JA
DIAGNOSIS AND TESTING (Continued)
ACCESSORY DRIVE BELT DIAGNOSIS

CONDITION POSSIBLE CAUSE CORRECTION

INSUFFICIENT ACCESSORY 1. Belt too loose. 1. Adjust belt tension.

OUTPUT DUE TO BELT SLIPPAGE
2. Belt excessively glazed or worn. 2. Replace and tighten as specified.

BELT SQUEAL WHEN 1. Belts too loose. 1. Adjust belt tension.

ACCELERATING ENGINE
2. Belts glazed. 2. Replace belts.

BELT CHIRP AT IDLE 1. Belts too loose. 1. Adjust belt tension.

2. Foreign material imbedded in 2. Replace belt.

belt.
3. Non-uniform belt. 3. Replace belt.
4. Misaligned pulley(s). 4. Align accessories.
5. Non-uniform groove or eccentric 5. Replace pulley(s).
pulley.

BELT ROLLED OVER IN GROOVE 1. Broken cord in belt. 1. Replace belt.

OR BELT JUMPS OFF 2. Belt too loose, or too tight. 2. Adjust belt tension.
3. Misaligned pulleys. 3. Align accessories.
4. Non-uniform grooves or eccentric 4. Replace pulley(s).
pulley.

ENGINE BLOCK HEATER COOLANT LEVEL—SERVICING

If unit does not operate, trouble can be in either
the power cord or the heater element. Test power NOTE: The cooling system is closed and designed
cord for continuity with a 110-volt voltmeter or 110- to maintain coolant level to the top of the radiator.
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light. When servicing requires a coolant level check in
the radiator, the engine must be off and not under
pressure. Drain several ounces of coolant from the
SERVICE PROCEDURES radiator drain cock while observing the Coolant
Recovery Container. Coolant level in the container
COOLANT LEVEL CHECK—ROUTINE should drop slightly. Then remove the radiator cap,
Do not remove radiator cap for routine cool- (Fig. 26), (Fig. 28), or (Fig. 27). The radiator should
ant level inspections. be full to the top. If not, and the coolant level in the
The coolant reserve system provides a quick visual recovery container is at the ADD mark there is a air
method for determining the coolant level without leak in the recovery system. Check hose or hose con-
removing the radiator cap. With the engine cold nections to the recovery container, radiator filler neck
and not running, simply observe the level of the or the pressure cap seal to the radiator filler neck for
coolant in the reserve tank. The level should be leaks.
between the minimum and maximum marks.

COOLANT—ADDING ADDITIONAL
NOTE: The radiator cap should not be removed.

When additional coolant is needed, it should be

added to the coolant recovery/reserve container (Fig.
26), (Fig. 28), or (Fig. 27). Use only 50/50 concentra-
tion of ethylene glycol type antifreeze and water
JA COOLING SYSTEM 7 - 21
SERVICE PROCEDURES (Continued)

Fig. 26 Coolant Recovery Container and Pressure Cap Locations—2.0L Engine

Fig. 27 Coolant Recovery Container and Pressure Cap Locations—2.4L Engine

COOLING SYSTEM—DRAINING PRESSURE BECAUSE SERIOUS BURNS FROM
COOLANT CAN OCCUR.
NOTE: Drain, flush, and fill the cooling system at
the mileage or time intervals specified in the Main- To drain cooling system move temperature selector
tenance Schedule in this Group. If the solution is for heater to full heat with engine running (to pro-
dirty or rusty or contains a considerable amount of vide vacuum for actuation). Without removing
sediment, clean and flush with a reliable cooling radiator pressure cap and with system not
system cleaner. Care should be taken in disposing under pressure, Shut engine off and open draincock
of the used engine coolant from your vehicle. (Fig. 29). The coolant reserve tank should empty
Check governmental regulations for disposal of first, then remove radiator pressure cap. (if not, see
used engine coolant. Testing Cooling System for leaks).

NOTE: To open draincock on vehicle equipped with

WARNING: DO NOT REMOVE THE COOLING SYS- 2.5L engine, use a 3/8 inch drive extension 3” long,
TEM PRESSURE CAP OR OPEN THE RADIATOR a 19mm socket with universal.
DRAINCOCK, WHEN SYSTEM IS HOT AND UNDER
7 - 22 COOLING SYSTEM JA
SERVICE PROCEDURES (Continued)

Fig. 28 Coolant Recovery Container and Pressure Cap Locations—2.5L Engine

REMOVAL AND INSTALLATION
WATER PUMP—2.0/2.4L ENGINES
REMOVAL
(1) Raise vehicle on a hoist. Remove right inner
splash shield.
(2) Remove accessory drive belts and power steer-
ing pump. Refer to Accessory Drive Belt service in
this section.
(3) Drain cooling system. Refer to Cooling System
Fig. 29 Draincock—Typical Draining in this section.
(4) Support engine from the bottom and remove
COOLING SYSTEM—REFILLING right engine mount.
First clean system to remove old glycol, see Cooling (5) Remove right engine mount bracket.
System Cleaning. (6) Remove timing belt, camshaft sprockets, and
Fill system with 50/50 glycol/water mix. Use anti- rear timing belt cover. Refer to Group 9, Engine for
freeze described in Coolant section. The thermostat procedure.
in the these engines allow air to flow through them. (7) Remove water pump attaching screws to engine
Continue filling system until full, this provides bet- (Fig. 30).
ter heater performance. Be careful not to spill
coolant on drive belts or the generator.
Fill coolant recovery/reserve container to at least
the FULL HOT mark with 50/50 glycol/water mix,
(Fig. 26), (Fig. 28), or (Fig. 27). It may be necessary
to add coolant to the recovery/reserve container to
maintain coolant level between the FULL HOT and
ADD mark after three or four warm-up/cool down
cycles and also, if any trapped air that has been
removed from cooling system.

Fig. 30 Water Pump

JA COOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 31).

CAUTION: Make sure O-ring is properly seated in

water pump groove before tightening screws. An
improperly located O-ring may cause damage to the
O-ring and cause a coolant leak.

Fig. 32 Water Pump—2.5L Engine

Fig. 31 Water Pump Body

(2) Assemble pump body to block and tighten
screws to 12 N·m (105 in. lbs.) (Fig. 30). Pressurize
cooling system to 15 psi with pressure tester and
check water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install rear timing belt cover, camshaft sprock-
ets, and timing belt. Refer to Group 9, Engine for
procedures.
(5) Install right engine mount bracket and engine
mount. Refer to Group 9, Engine for procedure.
(6) Fill cooling system. Refer to Cooling System
Filling for procedure outlined in this section. Fig. 33 Water Pump Inlet Tube
(7) Install power steering pump and accessory CAUTION: Keep the O-ring free of oil or grease.
drive belts. Refer to Accessory Drive Belts, in this
section.

WATER PUMP—2.5L ENGINE

REMOVAL
(1) Drain cooling system. Refer to Cooling System
Draining in this section.
(2) Remove right engine mount and bracket. Refer
to Group 9, Engine for procedure.
(3) Remove timing belt. Refer to Group 9, Engine
for procedure.
(4) Remove water pump mounting bolts.
(5) Separate pump from water inlet pipe (Fig. 33)
and remove pump (Fig. 32).

INSTALLATION
(1) Clean all gasket and O-ring surfaces on pump Fig. 34 Water Pipe O-Ring
and water pipe inlet tube. (3) Install new gasket on water pump and install
(2) Install new O-ring on water inlet pipe (Fig. 34). pump inlet opening over water pipe, press assembly
Wet the O-ring with water to facilitate assembly. to cause water pipe insertion into pump housing.
7 - 24 COOLING SYSTEM JA
REMOVAL AND INSTALLATION (Continued)
(4) Install pump to block mounting bolts and
tighten to 27 N·m (20 ft. lbs.).
(5) Install timing belt and right engine mount
bracket and mount. Refer to Group 9, Engine for pro-
cedure.
(6) Fill cooling system. See Cooling System Refill-
ing.
(7) Install accessory drive belts. Refer to Accessory
Drive Belts, in this section for procedure.

WATER PUMP INLET TUBE—2.0/2.4L

ENGINES
REMOVAL
(1) Drain cooling system. Refer to procedure in
this section.
(2) Remove upper radiator hose to access the hose Fig. 36 Water Pump Inlet Tube—Service
connections at the inlet tube.
(3) Remove lower radiator hose and heater hose THERMOSTAT
from the inlet tube (Fig. 35).
(4) Remove the 2 fasteners from that hold the inlet REMOVAL
tube to the block. (1) Drain cooling system to the thermostat level or
below.
(2) Remove coolant recovery system (CRS) hose
and thermostat/engine outlet connector bolts (Fig. 37)
and (Fig. 38) 2.0/2.4L Engines. 2.5L engine remove
inlet hose and coolant elbow from thermostat housing
(Fig. 39).
(3) Remove thermostat assembly, and clean sealing
surfaces.

Fig. 35 Water Pump Inlet Tube Hose Connections

(5) Rotate inlet tube while removing from the
engine block (Fig. 36).

INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 36).
(2) Lube O-ring with coolant and install into the
cylinder block opening.
Fig. 37 Thermostat/Engine Outlet Connector—2.0L
(3) Install 2 fasteners and tighten to 12 N·m (105
Engine
in. lbs.). INSTALLATION—2.0/2.4L ENGINE
(4) Connect lower radiator hose and heater hose to (1) Place the new thermostat assembly into the
inlet tube (Fig. 35). engine outlet connector. Align air bleed with notch on
(5) Install upper radiator hose. the cylinder head.
(6) Fill cooling system. Refer to procedure in this (2) Install engine outlet connector onto cylinder
section. head and tighten bolts to 12.5 N·m (110 in. lbs.).
Connect the coolant recovery system (CRS) hose.
JA COOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)

Fig. 38 Thermostat and Engine Outlet Connector—

2.4L Engine

Fig. 40 Cooling Module Mounting

WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.

(3) Drain cooling system. Refer to Cooling System

Draining in this section.
(4) Remove upper radiator crossmember (Fig. 40).
Refer to Group 23, Body for procedure.

Fig. 39 Thermostat, Housing and Inlet Elbow—2.5L CAUTION: Plastic tanks, while stronger then brass
Engine are subject to damage by impact, such as
(3) Fill cooling system. Refer to Cooling System wrenches.
Refilling in this section.
(5) Remove hose clamps and hoses from the radia-
tor.
INSTALLATION—2.5L ENGINE (6) Disconnect the fan wiring connector.
(1) Install thermostat into the recess in the ther-
(7) Remove fan module.
mostat housing.
(8) Disconnect automatic transmission hoses from
(2) Install inlet elbow and tighten the bolts to 19
cooler and plug off.
N·m (168 in. lbs.) (Fig. 39).
(9) Remove screw attaching support bracket for
(3) Fill cooling system. Refer to Cooling System
external transmission oil cooler lines to left side of
Refilling in this section.
radiator (if equipped).
(10) Disconnect the engine block heater wire, if
RADIATOR equipped.
REMOVAL CAUTION: Avoid bending the condenser inlet tube.
(1) Disconnect negative cable from auxiliary Care should be taken not to damage radiator or
jumper terminal. condenser cooling fins or water tubes during
(2) Remove air inlet resonator. Refer to Group 14, removal.
Fuel System for procedure.
7 - 26 COOLING SYSTEM JA
REMOVAL AND INSTALLATION (Continued)
(11) Remove screw attaching support bracket for (14) Operate engine until it reaches normal oper-
air conditioning lines from right side of radiator. ating temperature. Check cooling system and auto-
Remove support bracket. matic transmission for correct fluid levels.
(12) Remove the air conditioning condenser attach-
ing screws located at the front of the radiator (Fig. RADIATOR DRAINCOCK
41), if equipped. It is not necessary to discharge the
air conditioning system to remove radiator. REMOVAL
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as
wrenches.

(1) Turn the draincock stem counterclockwise to

unscrew the stem. When the stem is unscrewed to
the end of the threads, pull the stem (Fig. 42) from
the radiator tank.

NOTE: To open draincock on vehicle equipped with

2.5L engine, use a 3/8 inch drive extension 3” long,
a 19mm socket with universal.

Fig. 41 A/C Condenser to Radiator Mounting Screws

(13) Radiator can now be lifted free from engine
compartment. Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.

INSTALLATION
(1) Slide radiator and fan module down into posi-
tion, seat the radiator assembly lower rubber isola-
tors in the mount holes provided. Fig. 42 Draincock—Typical
(2) Attach air conditioning condenser to radiator, if
equipped. Tighten mounting screws to 5 N·m (45 in. INSTALLATION
lbs.). (1) Push the draincock assembly body into the
(3) Install air conditioning line support bracket tank opening until it snaps into place.
and attaching screw to right side of radiator. (2) Tighten the draincock stem by turning clock-
(4) Connect engine block heater wire, if equipped. wise to 2.0-2.7 N·m (18-25 in. lbs.) torque.
(5) Connect lower radiator hose and clamp.
(6) Install external transmission oil cooler line RADIATOR FAN, MOTOR AND SHROUD
support bracket and attaching screw to left side of
radiator (if equipped). REMOVAL
(7) Connect automatic transmission hoses; tighten (1) Remove upper radiator crossmember. Refer to
hose clamps to 2.5 N·m (22 in. lbs.). Group 23, Body for procedure.
(8) Install fan module. (2) Disconnect fan motor electrical connector.
(9) Connect fan motor electrical connection. (3) Remove fasteners attaching fan module to radi-
(10) Install upper radiator hose. Align hose so it ator (Fig. 44).
does not interfere with the accessory drive belt or (4) Remove fan module.
engine. Position hose clamp so it will not interfere
with the hood liner. FAN SERVICE
(11) Install upper radiator crossmember. Refer to There are no repairs to be made to the fan. If the
Group 23, Body for procedure. fan is warped, cracked, or otherwise damaged, it
(12) Connect negative cable to auxiliary jumper must be replaced with only the recommended part
terminal. for adequate strength, performance and safety.
(13) Fill cooling system with coolant. Refer to Cool- (1) To remove fan from motor shaft, bench support
ing System Refilling in this section. the motor and motor shaft while removing the fan
JA COOLING SYSTEM 7 - 27
REMOVAL AND INSTALLATION (Continued)
retaining clip, so that the shaft and motor will not be INSTALLATION
damaged by excessive force. Surface burr removal (1) Install fan module to radiator. Tighten shroud
may be required to remove fan from motor to radiator fasteners to 7.5 N·m (65 in. lbs.) (Fig. 44).
shaft (Fig. 43). Do not permit the fan blades to (2) Connect fan motor electrical connector. For
touch the bench. wiring diagrams of fan motor systems, refer to
Group 8W, Wiring Diagrams.
(3) Install upper radiator crossmember. Refer to
Group 23, Body for procedure.

ENGINE BLOCK HEATER

REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and
Refill of this section for procedure.
(2) Detach power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.

INSTALLATION
(1) Thoroughly clean core hole and heater seat
Fig. 43 Radiator Fan—Removal/Installation (Fig. 45).
(2) To install fan on motor shaft, slide the fan over (2) Insert heater assembly with electrical connec-
the shaft. Support motor and shaft while installing tor position at the top of the core hole.
fan retaining clip. (3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
The power cord must be secured in its retainer
clips, and not positioned so it could contact linkages
or exhaust manifolds and become damaged.

ACCESSORY DRIVE BELTS—2.0/2.4L ENGINES

AIR CONDITIONING COMPRESSOR AND
GENERATOR BELT
(1) Loosen T-Bolt locking nut A and pivot bolt B to
remove and install Poly V belt and/or adjust belt ten-
sion (Fig. 46).
Fig. 44 Fan Module (2) Tighten adjusting bolt to adjust belt tension to
FAN SHROUD specification shown in Belt Tension Chart.
All vehicles have fan shrouds to improve fan air (3) Tighten T-Bolt locking nut A and pivot bolt B to
flow efficiency. 54 N·m (40 ft. lbs.) (Fig. 46).
The shroud supports the electric fan motor and
fan. POWER STEERING PUMP BELT
(1) From the top of the vehicle loosen pivot bolt C.
FAN MOTOR SERVICE (2) From under the vehicle loosen locking bolts D
(1) Remove the motor fasteners from support. and E (Fig. 47).
Remove motor from support. (3) Install the belt. Adjust belt tension with 1/2 in.
(2) Reverse the above procedure for Installation. breaker bar installed in adjusting bracket. See Belt
Tighten the short fan motor fasteners to 3 N·m (25 Tension Chart.
in. lbs.) and tighten the tall fan motor fasteners to 5 (4) Tighten locking bolt D to 54 N·m (40 ft. lbs.)
N·m (45 in. lbs.). (Fig. 47).
7 - 28 COOLING SYSTEM JA
REMOVAL AND INSTALLATION (Continued)

Fig. 45 Engine Block Heaters

Accessory Drive Belt System—2.0/2.4L Engines

(5) Tighten locking bolt E to 28 N·m (250 in. lbs.).
(6) Tighten pivot bolt C to 54 N·m (40 ft. lbs.).

ACCESSORY DRIVE BELTS—2.5L ENGINE

AIR CONDITIONING AND GENERATOR BELT Fig. 46 Air Conditioning Compressor and Generator
Belt Adjustment
REMOVAL INSTALLATION
(1) Remove power steering pump drive belt. Refer (1) Refer to (Fig. 48) for belt routing.
to procedure in this section. (2) Install drive belt on pulleys.
(2) Loosen idler pulley locking bolt (Fig. 49).
(3) Loosen the adjusting screw to decrease the NOTE: Use Special Tool 7198, Belt Tension Gauge
idler pulley tension (Fig. 49). to check belt for proper tension.
(4) Remove belt.
JA COOLING SYSTEM 7 - 29
REMOVAL AND INSTALLATION (Continued)

Fig. 48 Accessory Drive Belt Routing—2.5L Engine

Fig. 47 Power Steering Belt Adjustment

BELT TENSION CHART

ACCESSORY DRIVE GAUGE

BELTS
2.0/2.4L ENGINES
New
Air Conditioning 667 N (150 lbs.)
Belt:
Compressor &
Generator Used
356 N (80 lbs.)
Belt:
New Fig. 49 Air Conditioning Compressor and Generator
578 N (130 lbs.) Belt Idler
Belt:
Power Steering Pump
Used POWER STEERING PUMP BELT
356 N (80 lbs.)
Belt:
REMOVAL
(1) From the top of the vehicle loosen pivot bolt
(Fig. 51).
(3) Tighten the adjusting screw until belt is ten- (2) Hoist vehicle and remove splash shield (Fig.
sioned to specifications. Refer to Belt Tension Chart 50).
for specifications. (3) From under the vehicle loosen the locking bolts
(4) Tighten idler pulley locking bolt to 54 N·m (40 F and G (Fig. 51).
ft. lbs.). Recheck belt for proper tension and adjust as
necessary. INSTALLATION
(5) Install power steering pump drive belt. (1) Install belt. Refer to (Fig. 48) for belt routing.

Air Conditioning and Generator Belt Tension Adjustment NOTE: Use Special Tool 7198, Belt Tension Gauge
To adjust the air conditioning and generator drive to check belt for proper tension.
belt, loosen the idler pulley locking bolt and adjust
belt tension by turning adjusting screw (Fig. 49). Use (2) Adjust belt tension with 1/2 in. drive breaker
Belt Tension Gauge and refer to Belt Tension Chart bar installed in adjusting bracket (Fig. 51). Use belt
for specification. Tighten pulley bolt to 54 N·m (40 ft. tension gauge and refer to Belt Tension Chart for
lbs.) after adjustment. tension specification.
7 - 30 COOLING SYSTEM JA
REMOVAL AND INSTALLATION (Continued)
BELT TENSION CHART

ACCESSORY DRIVE GAUGE

BELTS
2.5L ENGINE
Air Conditioning
New
Compressor & 667 N (150 lbs.)
Belt:
Generator Belt
Used
356 N (80 lbs.)
Belt:
Power Steering Pump New
578 N (130 lbs.)
Belt Belt:
Used
356 N (80 lbs.)
Belt:

CLEANING AND INSPECTION

WATER PUMP—2.0/2.4L ENGINES
Fig. 50 Accessory Drive Belt Splash Shield 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
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.

WATER PUMP—2.5L ENGINE

Fig. 51 Power Steering Belt Adjustment

(3) Tighten locking bolt G to 28 N·m (250 in. lbs.)
(Fig. 51).
(4) Tighten locking bolt F and the pivot bolt to 54
N·m (40 ft. lbs.).
Fig. 52 Water Pump Inspection
Power Steering Pump Belt Tension Adjustment
Refer to Power Steering Pump Belt installation Replace the water pump if it has any of the follow-
procedures for belt tensioning procedures. ing defects:
• Damage or cracks on the pump body.
JA COOLING SYSTEM 7 - 31
CLEANING AND INSPECTION (Continued)
• Coolant leaks, if the shaft seal is leaking, evi-
dent by traces of coolant leaks from vent hole A in
(Fig. 52).
• Impeller rubs inside of pump.
• Excessively loose or rough turning bearing.

ACCESSORY DRIVE BELT INSPECTION

Belt replacement under any or all of the following
conditions is required, excessive wear, frayed cords or
severe glazing.
Poly-V Belt system may develop minor cracks
across the ribbed side. These minor cracks are con-
sidered normal and acceptable. Cracks parallel are Fig. 54 Cooling System Pressure Cap
not (Fig. 53). CLEANING COOLING SYSTEM
Drain cooling system (see: Draining Cooling Sys-
NOTE: Do not use any type of belt dressing or tem) and refill with clean water (see: Refilling
restorer on Poly-V Belts. Cooling System). Run engine with radiator cap
installed until upper radiator hose is hot. Stop
engine and drain water from system. If water is
dirty, fill, run and drain the system again until water
runs clear.

RADIATOR FLUSHING
Drain cooling system and remove radiator hoses
from engine. Install suitable flushing gun in radiator
lower hose. Fill radiator with clean water and turn
on air in short blasts.

CAUTION: Internal radiator pressure must not

exceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedure until water runs
clear.

ENGINE FLUSHING
Drain radiator (see: Cooling System Draining)
and remove hoses from radiator. Remove engine ther-
mostat and reinstall thermostat housing. A gasket
may be needed to seal the housing to cylinder head
Fig. 53 Drive Belt Wear Pattern
because the seal is part of thermostat. Install suit-
COOLING SYSTEM CAP able flushing gun to thermostat housing hose. Turn
Hold the cap in your hand, right side up (Fig. 54). on water, and when engine is filled, turn on air, but
The vent valve at the bottom of the cap should open. no higher than 138 kPa (20 psi) in short blasts. Allow
If the rubber gasket has swollen, preventing the engine to fill between blasts of air. Continue this pro-
valve from opening, replace the cap. cedure until water runs clean. Install thermostat and
Hold the cleaned cap in your hand, upside down. fill cooling system. Refer to (Cooling System Refill-
If any light can be seen between vent valve and the ing) for procedure.
rubber gasket, replace the cap. Do not use a
replacement cap that has a spring to hold the REVERSE FLUSHING
vent shut. Reverse flushing of the cooling system is the forc-
A replacement cap must be of the type designed for ing of water through the cooling system, using air
coolant reserve systems. This design ensures coolant pressure in a direction opposite to that of the normal
return to the radiator. flow of water. This is only necessary with dirty sys-
tems and evidence of partial plugging.
7 - 32 COOLING SYSTEM JA
CLEANING AND INSPECTION (Continued)

CHEMICAL CLEANING SPECIFICATIONS

One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor- COOLING SYSTEM CAPACITY
rosion products are carried to the radiator and depos- COOLING SYSTEM CAPACITY CHART
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be
removed with a two part cleaner (oxalic acid and Engine 2.0L 2.4L 2.5L
neutralizer) available in auto parts outlets. Follow COOLANT CAPACITY*
manufacturers directions for use. Liters 8.0 8.5 10.0
U.S. Qts. 8.5 9.0 10.5
ADJUSTMENTS *Includes Heater and Coolant Recovery System

BELT TENSION GAUGE METHOD

For conventional belts and Poly-V belts, use belt TORQUE
tensioning gauge Special Tool 7198 to obtain proper
belt tension. DESCRIPTION TORQUE
Adjust the belt tension for a New or Used belt as A/C Condenser to Radiator
prescribed in the Belt Tension Chart. Fasteners . . . . . . . . . . . . . . . . . 5 N·m (45 in. lbs.)
Thermostat Housing 2.0/2.4L
BELT TENSION CHART
Bolts . . . . . . . . . . . . . . . . . 12.5 N·m (110 in. lbs.)
Thermostat Housing 2.5L
ACCESSORY DRIVE GAUGE Bolts . . . . . . . . . . . . . . . . . . . 19 N·m (168 in. lbs.)
BELTS Water Pump Mounting 2.0/2.4L
2.0/2.4/2.5L ENGINES Bolts . . . . . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
New Water Pump Mounting 2.5L
Air Conditioning 667 N (150 lbs.) Bolts . . . . . . . . . . . . . . . . . . . 24 N·m (205 in. lbs.)
Belt:
Compressor & Water Pump Inlet Tube to Block
Generator Used
356 N (80 lbs.) Bolts . . . . . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Belt:
Water Pump Inlet Pipe to Cylinder Head 2.5L
New
578 N (130 lbs.) Fasteners . . . . . . . . . . . . . . . 14 N·m (123 in. lbs.)
Belt:
Power Steering Pump Fan Module to Radiator
Used Fasteners . . . . . . . . . . . . . . . . . 7 N·m (65 in. lbs.)
356 N (80 lbs.)
Belt: Fan Motor to Shroud
Fasteners . . . . . . . . . . . . . . . . . 5 N·m (45 in. lbs.)
Transmission Oil Cooler Hose
Clamps . . . . . . . . . . . . . . . . . . . 2 N·m (18 in. lbs.)
JA COOLING SYSTEM 7 - 33

SPECIAL TOOLS
COOLING

Hose Clamp Pliers 6094

Belt Tension Gauge 7198

Coolant Refractometer 8286