cooling CHEVROLET DYNASTY 1993 Service Manual

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension/Driveshafts
5Brakes
6Manual Transaxle Clutch
7Cooling System
9Engine
11Exhaust System and Intake Manifold
13Frame and Bumpers
19Steering
21Transaxle
22Wheels/Tires
23Body
24Heating/Air Conditioning
Component and System Index
Service Manual Comment Forms (Rear of Manual)

COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page
BODY ................................... 23-1
AA-VEHICLE BODY COMPONENT SERVICE .......23-11
AC-VEHICLE BODY COMPONENT SERVICE .......23-37
AG-VEHICLE BODY COMPONENT SERVICE .......23-52
AJ/27-VEHICLE CONVERTIBLE BODY COMPONENT SERVICE ............................ 23-86
AJ-VEHICLE BODY COMPONENT SERVICE .......23-71
AP-VEHICLE BODY COMPONENT SERVICE .......23-97
AY-VEHICLE BODY COMPONENT SERVICE .......23-133
BODY DIAGNOSTIC PROCEDURES .............23-2
GENERAL SERVICE INFORMATION .............23-1
PAINT ................................. 23-4
POWER SUNROOF ........................ 23-6
WINDSHIELD ............................ 23-9
BRAKES ..................................5-1
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 10 AC/Y BODY ......................... 5-72
ANTI-LOCK BRAKE SYSTEMÐBENDIX ANTI-LOCK 6 AA,AG,AJ,AP BODY .................... 5-113
BRAKE DISC (ROTOR) ...................... 5-53
BRAKE SUPPORT ASSEMBLY .................5-25
FRONT DISC BRAKES ...................... 5-31
GENERAL INFORMATION .....................5-1
HYDRAULIC SYSTEM CONTROL VALVES .........5-26
KELSEY HAYES DOUBLE PIN FAMILY CALIPER .....5-35
KELSEY HAYES DOUBLE PIN NON-FAMILY CALIPER ............................. 5-38
MASTER CYLINDER ....................... 5-66
PARKING BRAKES ........................ 5-57
POWER BRAKES ......................... 5-68
REAR DISC BRAKES ....................... 5-45
REAR WHEEL DRUM BRAKES ................5-18
SERVICE ADJUSTMENTS .....................5-4
WHEEL BEARINGS ........................ 5-70
WHEEL CYLINDERS ....................... 5-23
COOLING SYSTEM ...........................7-1
ACCESSORY DRIVE BELTS ................... 7-24
ENGINE BLOCK HEATER .................... 7-28
GENERAL INFORMATION .....................7-1
SERVICE PROCEDURES ..................... 7-10
SPECIFICATIONS ......................... 7-29
ENGINE ..................................9-1
2.2/2.5L ENGINES .........................9-8
3.0L ENGINE ............................ 9-66
3.3/3.8L ENGINE ......................... 9-98
STANDARD SERVICE PROCEDURES .............9-1
EXHAUST SYSTEM AND INTAKE MANIFOLD .........11-1
GENERAL INFORMATION .................... 11-1
SERVICE PROCEDURES ..................... 11-4
TORQUE SPECIFICATION ................... 11-25
FRAME AND BUMPERS ....................... 13-1
BUMPER AND FASCIA ...................... 13-1
FRAME ................................ 13-9
HEATING AND AIR CONDITIONING ...............24-1
AUTOMATIC TEMPERATURE CONTROL (ATC) .....24-66 COMPONENT SERVICE PROCEDURES
..........24-47
FIXED DISPLACEMENT COMPRESSORÐMODEL 10PA17............................. 24-24
FIXED DISPLACEMENT COMPRESSORÐMODEL SD709P ............................. 24-38
FIXED DISPLACEMENT COMPRESSORÐMODEL TR105 .............................. 24-32
GENERAL INFORMATION .................... 24-1
HEATER AND A/C PERFORMANCE TESTS .........24-6
REFRIGERANT SERVICE PROCEDURES ..........24-8
VACUUM CONTROL SYSTEM DIAGNOSIS .........24-4
VARIABLE DISPLACEMENT COMPRESSORÐMODEL 6C17 ............................... 24-13
INTRODUCTION .......................... Intro.-1
LUBRICATION AND MAINTENANCE ................0-1
CHASSIS AND BODY ....................... 0-19
DRIVETRAIN ............................ 0-16
ENGINE ................................0-8
GENERAL INFORMATION .....................0-1
MANUAL TRANSAXLE CLUTCH ...................6-1
STEERING ................................ 19-1
ACUSTAR STANDARD AND TILT STEERING COLUMN ............................ 19-28
AUTOMATIC TRANSMISSION SHIFTER/IGNITION INTERLOCK .......................... 19-36
GENERAL INFORMATION .................... 19-1
POWER STEERING GEAR ................... 19-25
POWER STEERING PUMPS ..................19-1
SPECIFICATIONS AND TIGHTENING REFERENCE . . . 19-42
SUSPENSION AND DRIVESHAFTS .................2-1
AUTOMATIC AIR LOAD LEVELING SYSTEM ........2-59
AUTOMATIC AIR SUSPENSION ................2-73
DRIVESHAFTS ........................... 2-25
FRONT SUSPENSION .......................2-2
FRONT SUSPENSION SERVICE PROCEDURES .......2-5
GENERAL INFORMATION .....................2-1
REAR (STUB) AXLE ALIGNMENT ALL MODELS .....2-89
REAR SUSPENSION ....................... 2-50
SPECIFICATIONS ......................... 2-91
TRANSAXLE .............................. 21-85
41TE FOUR SPEED AUTOMATIC TRANSAXLE ......21-85
41TE FOUR SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 21-170
41TE ON-BOARD DIAGNOSTICS .............21-145
A-523, A-543, and A-568 MANUAL TRANSAXLE ....21-1
SPECIFICATIONS ........................ 21-183
THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE .......................... 21-35
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 21-162
WHEELSÐTIRES ........................... 22-1
SPECIFICATIONS ......................... 22-8
TIRE SERVICE PROCEDURES .................22-1
WHEELS SERVICE PROCEDURES ..............22-6

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol on the label. At the bottom NLGI symbol is the usage and qual-
ity identification letters. Wheel bearing lubricant is
identified by the letter ``G''. Chassis lubricant is iden-
tified by the letter ``L''. The letter following the us-
age letter indicates the quality of the lubricant. The
following symbols indicate the highest quality.
FLUID CAPACITIES
Fuel Tank
AP,AG and AJ ......................................53 L (14 gal.)
AA,AC and AY .....................................60 L (16 gal.)
AA-Flexible Fuel ..................................68 L (18 gal.)
Engine Oil
All.........................................................3.8 L (4.5 qts.)
Cooling System
2.2L ......................................................8.5 L (9.0 qts.)
2.5L ......................................................8.5 L (9.0 qts.)
3.0L ......................................................9.0 L (9.5 qts.)
3.3L ......................................................9.0 L (9.5 qts.)
3.8L ......................................................9.0 L (9.5 qts.)
Includes heater and coolant recovery bottle
Automatic Transaxle
Estimated Service Fill
ALL ......................................................3.8 L (4.0 qts.)
Overhaul Fill Capacity with Torque Converter
Empty
3-speed Fleet .......................................8.7 L (9.2 qts.)
3-speed .................................................8.2 L (8.8 qts.)
4-speed Electronic ................................9.4L (9.9 qts.)
Manual Transaxle
All ..........................................................9.4L (9.9 qts.)
Fill to bottom of fill hole.
Power Steering
All ...........................................................75L (1.5 pts.)
PARTS REQUIRING NO LUBRICATION
Many components on a Chrysler Corporation vehi-
cle require no periodic maintenance. Some compo-
nents are sealed and permanently lubricated. Rubber
bushings can deteriorate or limit damping ability if
lubricated. The following list of components require
no lubrication: ²
Air Pump
² Generator Bushings
² Drive Belts
² Drive Belt Idler/Tensioner Pulley
² Front Wheel Bearings
² Rubber Bushings
² Starter Bearings/Bushings
² Suspension Strut Bearings
² Throttle Control Cable
² Throttle Linkage
² Water Pump Bearings
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PER-
SONAL INJURY CAN RESULT. DO NOT JUMP START WHEN BATTERY INDICA-
TOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON HANDS
OR WRISTS TO AVOID INJURY BY ACCIDENTAL
ARCHING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DE-
VICE, DO NOT ALLOW BATTERY VOLTAGE TO EX-
CEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually in-
spect engine compartment for:
² Battery cable clamp condition, clean if necessary.
² Frozen battery.
² Yellow or bright color test indicator, if equipped.
² Low battery fluid level.
² Generator drive belt condition and tension.
² Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, turn off all accessories, place gear selector in
park or neutral, set park brake and operate engine
at 1200 rpm.
NLGI SYMBOL
0 - 4 LUBRICATION AND MAINTENANCE Ä

ENGINE INDEX
page page
Engine Oil Filter .......................... 9
Battery ................................ 15
Crankcase Ventilation System ............... 13
Drive Belts ............................. 14
Emission Control System ................... 14
Engine Air Cleaner ....................... 11
Engine Cooling System .................... 10 Engine Oil
............................... 8
Frequency of Engine Oil and Filter Changes ..... 8
Fuel Filter .............................. 14
Fuel Recommendations .................... 14
Ignition Cables, Distributor Cap, and Rotor ..... 14
Rubber and Plastic Component Inspection ...... 15
Spark Plugs ............................ 14
FREQUENCY OF ENGINE OIL AND FILTER
CHANGES
ENGINE OIL
Road conditions as well as your kind of driving af-
fect the interval at which your oil should be changed.
Check the following to determine if any apply to you:
² Frequent short trip driving less than 8 kilometers
(5 miles)
² Frequent driving in dusty conditions
² Frequent trailer towing
² Extensive idling (such as vehicle operation in stop
and go traffic)
² More than 50% of your driving is at sustained
high speeds during hot weather, above 32ÉC (90ÉF) If any of these apply to you then change your en-
gine oil every 4 800 kilometers (3,000 miles) or 3
months, whichever comes first. If none of these apply to you then change your oil
every 12 000 kilometers (7,500 miles) or 6 months,
whichever comes first. If none of these apply and the vehicle is in com-
mercial type service such as, Police, Taxi or Limou-
sine and principally used for highway driving of 40
kilometers (25 miles) or more between stations, the
engine oil should be changed every 8 000 kilometers
(5,000 miles) or 6 months, whichever comes first.
FLEXIBLE FUEL VEHICLES
Flexible fuel is corrosive and contributes to engine
oil contamination. When flexible fuel is being used,
the engine oil should be changed every 8 000 kilome-
ters (5,000 miles) or 6 months, whichever comes first.
OIL FILTER
The engine oil filter should be replaced with a new
filter at every second oil change.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED
BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EX-
POSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR
GOVERNMENT AGENCY FOR LOCATION OF COL-
LECTION CENTER IN YOUR AREA.
BREAK-IN PERIOD
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
On a Chrysler Corporation vehicle an extended
break-in period is not required. Driving speeds of not
over 80-90 km/h (50-55 mph) for the first 100 km (60
miles) is recommended. Hard acceleration and high
engine rpm in lower gears should be avoided.
SELECTING ENGINE OIL
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase lu-
bricant. Engine or Turbocharger failure can result.
The factory fill engine oil is a high quality, energy
conserving, crankcase lubricant. The Recommended
SAE Viscosity Grades chart defines the viscosity
grades that must be used based on temperature in
the region where vehicle is operated and optional
equipment.
NON-FLEXIBLE FUEL VEHICLES Chrysler Corporation recommends that Mopar mo-
tor oil, or equivalent, be used when adding or chang-
ing crankcase lubricant. The API symbol (Fig. 1) on
the container indicates the viscosity grade, quality
and fuel economy ratings of the lubricant it contains.
Use ENERGY CONSERVING II motor oil with API
SERVICE SG or SG/CD classification.
0 - 8 LUBRICATION AND MAINTENANCE Ä

ENGINE COOLING SYSTEM
WARNINGS AND PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO
NOT STORE IN OPEN OR UNMARKED CONTAIN-
ERS. WASH SKIN AND CLOTHING THOROUGHLY
AFTER COMING IN CONTACT WITH ETHYLENE
GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROP-
ERLY, CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CEN-
TER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PER-
SONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PER-
FORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Do not use straight antifreeze as engine
coolant, inadequate engine running temperatures
can result. Do not operate vehicle without proper concentra-
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engine cooling system will develop internal
pressure of 97 to 123 kPa (14 to 18 psi) at normal op-
erating temperature. Allow the vehicle approxi-
mately one half hour to cool off before opening the
cooling system. As an indicator of pressure, squeeze
the upper radiator hose between index finger and
thumb. If it collapses with little effort the system
would have low internal pressure and should be safe
to open to the first safety notch of the radiator cap.
Refer to Group 7, Cooling System.
COOLING SYSTEM INSPECTION
Coolant level (Fig. 5) should be inspected when
other engine compartment service is performed or
when coolant leak is suspected. Coolant recovery
tank level should read between the MIN and MAX
marks, located on the side of recovery tank, when the
engine is at normal operating temperature. Normal
coolant level maintenance does not require the re-
moval of radiator cap. Cooling system freeze protec-
tion should be tested at the onset of the winter
season or every 12 months. Service is required if
coolant is low, contaminated, rusty or freeze protec-
tion is inadequate. To properly test cooling system,
see Group 7, Cooling System.
The cooling system factory fill is a mixture of 50%
Glycol based antifreeze and 50% water. Using a suit-
able hydrometer, measure antifreeze concentration in
the radiator when the engine is cool. If the cooling
system has recently been serviced, allow coolant to
circulate for at least 20 minutes before taking hy-
drometer reading. Properly mixed coolant will pro-
tect the cooling system to -37ÉC (-35ÉF). If the freeze
protection is above -28ÉC (-20ÉF), drain enough cool-
ant from the cooling system to allow room to add an-
Fig. 3 Remove Oil Filter
Fig. 4 Install Oil Filter
Fig. 5 Coolant Recovery Tank
0 - 10 LUBRICATION AND MAINTENANCE Ä

tifreeze to achieve adequate protection. A mix table
on the coolant container indicates the amount of an-
tifreeze required to winterize the cooling system
based on the capacity, see Capacity Chart in General
Information section of this group.
SELECTING ANTIFREEZE
Chrysler Corporation recommends Mopar Anti-
freeze/Summer Coolant, or equivalent be used to win-
terize and protect cooling system.
RADIATOR CAP
The radiator cap must be secure to provide proper
pressure release and coolant recovery. Inspect and
test radiator cap when cooling system service is per-
formed or when problem is suspected.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the inter-
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
this group. For proper service instructions see Group
7, Cooling System.
ENGINE AIR CLEANER
The engine air cleaner should be serviced at the in-
tervals described in the Lubrication and Mainte-
nance Schedules. Refer to General Information
section of this group. Additional information can be
found in Group 14, Fuel System and Group 25, Emis-
sion System. Inspect all air cleaner hoses or tubes for
damage or leaks when other engine compartment
service is performed. Replace faulty components.
AIR CLEANER SERVICE
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine con-
troller to function correctly. Do not immerse paper air filter element or temper-
ature sensor in cleaning solvents, damage can re-
sult.
TO SERVICE AIR CLEANER ASSEMBLY: (1) Raise hood of vehicle and inspect all air cleaner
components for damage or improper attachment. (2) Remove air cleaner cover (Fig. 6, 7, 8, 9, or 10).
(3) Remove paper air filter element from air
cleaner body. Hold a shop light on throttle body side
of element. Inspect air intake side of element. If light
is visible through element, blow dust from element
(Fig. 11) and reuse. If element is saturated with oil
or light is not visible, replace filter. If element is sat-
urated with oil, perform crankcase ventilation sys-
tem tests. (4) Remove fiber crankcase filter (Fig. 6, 7, 8, 9, or
10) and clean with solvent, squeeze filter dry and ap- ply small amount of engine oil. If a metallic mesh is
used to retain fiber filter, clean mesh with solvent
and reuse.
(5) Clean inside of air cleaner cover and body with
vacuum or compressed air. If oily, wash with solvent. To Install, reverse the preceding operation.
Fig. 6 Air CleanerÐ3.0L Engine
Fig. 7 Air CleanerÐFlexible Fuel Engine
Fig. 8 Air CleanerÐ16 Valve Engine
Ä LUBRICATION AND MAINTENANCE 0 - 11

PCV SYSTEM TEST
Refer to group 25, Emission Control System for
proper procedures to test PCV system.
FUEL RECOMMENDATIONS
Chrysler Corporation recommends that only fuel pur-
chased from a reputable retailer be used. Use high qual-
ity, unleaded gasoline to provide satisfactory
driveability and highest fuel economy. Gasoline contain-
ing detergent and corrosion control additives are desire-
able. If the engine develops spark knock (audible ping),
poor performance, hard starting or stalling, purchase
fuel from another source. Engine performance can vary
when using different brands of gasoline with the same
octane rating. Occasional light engine spark knock un-
der heavy acceleration, at low speed or when vehicle is
heavily loaded is not harmful. Extended periods of
spark knock under moderate acceleration or at cruising
speed can damage the engine. The cause of excessive
spark knock condition must be diagnosed and corrected.
For diagnostic procedures refer to Group 14, Fuel Sys-
tem and Powertrain Diagnostic Procedures manual.
SELECTING GASOLINE
CAUTION:Do not use fuel containing METHANOL
(methyl or wood alcohol), damage to fuel system
will result. Do not use leaded gasoline, damage to catalytic
converter will result and vehicle will not conform to
emission control standards.
ETHANOL, MTBE OR ETBE BLENDS
All Chrysler Corporation vehicles are designed to
use unleaded gasoline ONLY. Gasohol blends, con-
taining 10% Ethanol (ethyl or grain alcohol) 90% un-
leaded gasoline can be used provided it has adequate
octane rating. Fuel blends containing up to 15% MTBE (Methyl
Tertiary Butyl Ether) and 85% unleaded gasoline can
be used. Fuel blends containing up to 17% ETBE
(Ethyl Tertiary Butyl Ether) and 83% unleaded gas-
oline can also be used. Fuel blended with ethanol, MTBE or ETBE are
also referred to as reformulated or clean air gasoline.
These fuels contribute less emissions to the atmo-
sphere. Chrysler Corporation recommends that
blended fuels be used when available
METHANOL BLENDS Using gasoline blended with methanol can result
in starting and driveability problems. Deterioration
of fuel system components will result. Methanol in-
duced problems are not the responsibility of Chrysler
Corporation and may not be covered by the vehicle
warranty. NON-TURBOCHARGED ENGINES
Use regular unleaded gasoline having a minimum
octane rating of 87 (R+M)/2. Higher octane premium
unleaded gasoline can be used if desired.
2.2L 16 VALVE TURBOCHARGED ENGINE
Use premium unleaded gasoline having a mini-
mum octane rating of 91 (R+M)/2. Gasoline with oc-
tane rating less than 91 (R+M)/2 can be used if
recommended gasoline is not available. Low octane
gasoline will reduce engine performance.
FLEXIBLE FUEL VEHICLES
CAUTION: Do not use 100% methanol, damage to
fuel system can result. Use unleaded regular gasoline having a minimum
octane rating of 87 (R=M)/2 and M85 fuel that is
85% methanol and 15% unleaded gasoline, or a mix-
ture of these two.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nostic and service procedures refer to Group 14, Fuel
System,
IGNITION CABLES, DISTRIBUTOR CAP, AND
ROTOR
Inspect and test ignition cables, distributor cap and
rotor when the spark plugs are replaced. Oil and
grime should be cleaned from the ignition cables and
distributor cap to avoid possible spark plug fouling.
Mopar, Foamy Engine Degreaser, or equivalent is
recommended for cleaning the engine compartment.
For proper service and diagnostic procedures refer to
Group 8D, Ignition System.
SPARK PLUGS
Ignition spark plugs should be replaced at the
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. For proper service pro-
cedures refer to Group 8D, Ignition Systems.
DRIVE BELTS
Inspect and adjust drive belts at the interval de-
scribed in the Lubrication and Maintenance Sched-
ules. Refer to General Information section of this
group. For proper inspection and adjustment proce-
dures, see Group 7, Cooling System.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses
when other under hood service is performed. Refer to
emission system Vacuum Hose Label located on the
0 - 14 LUBRICATION AND MAINTENANCE Ä

COOLING SYSTEM
CONTENTS
page page
ACCESSORY DRIVE BELTS ............... 24
ENGINE BLOCK HEATER ................. 28
GENERAL INFORMATION .................. 1 SERVICE PROCEDURES
.................. 10
SPECIFICATIONS ....................... 29
GENERAL INFORMATION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
COOLING SYSTEM
The cooling system consists of an engine cooling
module, thermostat, coolant, a water pump to circu-
late the coolant. The engine cooling module may con-
sist of a radiator, electric fan motor, shroud, radiator
pressure cap, coolant reserve system, transmission oil
cooler, hoses, clamps, air condition condenser, trans-
mission oil lines and charge air cooler.
² When Engine is cold: Thermostat is closed, cooling
system has no flow through the radiator. The coolant
bypass flows through the engine only. ²
When Engine is warm: Thermostat is open, cooling
system has bypass flow and coolant flow through ra-
diator. Its primary purpose is to maintain engine temper-
ature in a range that will provide satisfactory engine
performance and emission levels under all expected
driving conditions. It also provides hot water (cool-
ant) for heater performance and cooling for auto-
matic transmission oil. It does this by transferring
heat from engine metal to coolant, moving this
heated coolant to the radiator, and then transferring
this heat to the ambient air. Coolant flow circuits for 2.2L and 2.5L engine
equipped vehicles are shown in (Fig 1). Turbocharged
equipped engines coolant routing and plumbing are
shown in (Fig 2). The 3.0L engine coolant routing is
shown in (Fig 3). The 3.3L and 3.8L engine coolant
routing is shown in (Fig 5).
Fig. 1 Cooling System OperationÐ2.2/2.5L Engines
Ä COOLING SYSTEM 7 - 1

TURBOCHARGER COOLANT ROUTING
Engines equipped with a Turbocharger maintain a
continuous engine coolant flow through the Turbo-
charger bearing housing water jacket. Hose and tube
assemblies provide a closed loop coolant flow from
the cylinder block water jacket to the turbocharger
housing and back to the cylinder head waterbox (Fig.
2). Excluding heated intake manifold hose routing
(hose is routed from waterbox directly to heater), all
other system functions are essentially the same as
shown for standard engines. During any reassembly procedures all pipe fittings
in water jacket, bearing housing and waterbox re-
quire cleaning and application of thread sealant for
entire length of threads. Tighten all fittings to
torque specified in (Fig 2).
WATER PIPESÐ3.0L
The 3.0L engines use metal piping beyond the
lower radiator hose to route coolant to the suction
side of water pump, located in the V of the cylinder
banks. These pipes are also provided with inlet nipples for
thermostat bypass and heater return coolant hos-
es,and brackets for rigid engine attachment. The
pipes employ O-rings for sealing at their interconnec-
tion and to the water pump (Fig. 4).
Fig. 2 Turbocharger-Tube Hose AssembliesÐTurbo III Engine
Fig. 3 Cooling System OperationÐ3.0L Engine
7 - 2 COOLING SYSTEM Ä

Fig. 4 Engine Inlet Coolant Pipes
Fig. 5 Cooling System OperationÐ3.3/3.8L Engines
Ä COOLING SYSTEM 7 - 3