Drive belt removal DODGE RAM 1500 1998 2.G Workshop Manual

exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINECOOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of the top of the thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
DIAGNOSIS AND TESTING - COOLING SYSTEM DIESEL ENGINE
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS
LOW1. Vehicle is equipped with a heavy
duty cooling system.1. None. System operating normally.
NOTE: Information on dash cluster
is displayed based on broadcast
datd from ECM. DTC will be set for
engine sensore circuit concern.2. Thermostat stuck open 2. Inspect and test thermostat.
3. Coolant level low. 3. Fill cooling system. (Refer to 7 -
COOLING - STANDARD
PROCEDURE)
4. Temperature gauge not
functioning correctly.4. Check cluster (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
5. Engine sensor stuck in range 5. Monitor sensor with DRB III to
verify sensor reading changes with
increasing temperature.
6. Engine sensor failed out of
range.A DTC will be set.
7. Electronically Controlled Vicsous
Fan Drive not operating properly.7. Check Electronically Controlled
Viscous Fan Drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
DRCOOLING 7 - 7
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
Temperature gauge reading is
inconsistent (fluctuates, cycles or is
erratic)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and
repair if necessary. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING).
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)3. A normal condition. No correction
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).5. Check and correct coolant leaks.
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
REMOVAL).
8. Loose accessory drive belt.
(water pump slipping)8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK1. Pressure relief valve in radiator
cap is defective.1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
7 - 14 COOLINGDR
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION1. Has a Diagnostic trouble Code
(DTC) been set?1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Obstructions in heater hose/
fittings3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - REMOVAL). If a
slipping belt is detected, (Refer to 7
- COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS
AND TESTING). If heater core
obstruction is detected, (Refer to 24
- HEATING & AIR
CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP
AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or air
flow to blow it away.1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.1. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION) Adjust coolant
mixture as necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.1. A normal condition. No repair is
necessary.
7 - 16 COOLINGDR
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONER - 3.7L / 4.7L
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
BELT TENSIONER-5.7L
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
BELT TENSIONER - 5.9L DIESEL
DESCRIPTION.........................23
OPERATION...........................23REMOVAL.............................23
INSTALLATION.........................24
DRIVE BELT - 3.7L / 4.7L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT.........................24
REMOVAL.............................26
INSTALLATION.........................26
DRIVE BELT - 5.9L DIESEL
DIAGNOSIS AND TESTINGÐACCESSORY
DRIVE BELT.........................27
REMOVAL.............................29
INSTALLATION.........................29
BELT TENSIONER - 3.7L / 4.7L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
3.7L or 4.7L engine. These engines are equipped with
an automatic belt tensioner (Fig. 1). The tensioner
maintains correct belt tension at all times. Due to
use of this belt tensioner, do not attempt to use a belt
tension gauge on 3.7L or 4.7L engines.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
REMOVAL
On 3.7L and 4.7L engines, the tensioner is
equipped with an indexing tang on back of ten-
sioner and an indexing stop on tensioner hous-
ing. If a new belt is being installed, tang must
be within approximately 24 mm (.94 inches) of
indexing stop. Belt is considered new if it has
been used 15 minutes or less.
If the above specification cannot be met, check for:²The wrong belt being installed (incorrect length/
width)
²Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, water pump, idler pul-
ley or generator)
²A pulley on an engine accessory being loose
²Misalignment of an engine accessory
²Belt incorrectly routed.
NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum tension
indicator. Tensioner travel stops at this point.
Fig. 1 AUTOMATIC BELT TENSIONER
1 - AUTOMATIC TENSIONER ASSEMBLY
DRACCESSORY DRIVE 7 - 21

(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner assembly from mounting
bracket (Fig. 2).
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) An indexing slot is located on back of tensioner.
Align this slot to the head of the bolt on the front
cover. Install the mounting bolt. Tighten bolt to 41
N´m (30 ft. lbs.).
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Check belt indexing marks (Fig. 1).
BELT TENSIONER-5.7L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
5.7L engines. This engines is equipped with an auto-
matic belt tensioner. The tensioner maintains correct
belt tension at all times (Fig. 3). Due to the use of
this belt tensioner, do not attempt to use a belt ten-
sion gauge on 5.7L engine.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
REMOVAL
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner and mounting bracket.
(3) Remove the tensioner assembly from the
mounting bracket.
(4)
Fig. 2 AUTOMATIC BELT TENSIONER - 3.7L/4.7L
ENGINE
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 N´m (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
Fig. 3 Automatic Belt Tensioner
1 - TENSIONER
2 - BOLT
7 - 22 ACCESSORY DRIVEDR
BELT TENSIONER - 3.7L / 4.7L (Continued)

INSTALLATION
(1) Install tensioner on to the mounting bracket.
Tighten bolt to 41 N´m (30 ft. lbs.).
(2) Install tensioner and bracket assembly
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
BELT TENSIONER - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 5) and
remove tensioner.
Fig. 4 Accessory Drive Belt - 5.9L Diesel
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
Fig. 5 AUTOMATIC BELT TENSIONER 5.9L DIESEL
ENGINE
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
DRACCESSORY DRIVE 7 - 23
BELT TENSIONER-5.7L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix4. Replace belt
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic (spring load) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts it's stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 7).
INSTALLATION
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 7).
(2) Install new belt (Fig. 7). Route the belt around
all pulleys except the idler pulley. Rotate the ten-
sioner arm until it contacts it's stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator (Fig. 8). On 4.7L Engines only, the gap
between the tang and the housing stop (measure-
ment A) must not exceed 24 mm (.94 inches). If the
measurement exceeds this specification replace the
serpentine accessory drive belt.
Fig. 7 BELT ROUTING 3.7L / 4.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 8 Accessory Drive Belt Wear Indicator±4.7L
Engine
1 - AUTOMATIC TENSIONER ASSEMBLY
7 - 26 ACCESSORY DRIVEDR
DRIVE BELT - 3.7L / 4.7L (Continued)

REMOVAL
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
Drive belts on diesel engines are equipped with a
spring loaded automatic belt tensioner.
This belt tensioner will be used on all belt config-
urations, such as with or without air conditioning.
For more information, (Refer to 7 - COOLING/AC-
CESSORY DRIVE/BELT TENSIONERS - DESCRIP-
TION).
(1) A 1/2 inch square hole is provided in the auto-
matic belt tensioner. Attach a 1/2 inch drive-long
handle ratchet to this hole.(2) Rotate ratchet and tensioner assembly clock-
wise (as viewed from front) until tension has been
relieved from belt.
(3) Remove belt from water pump pulley first.
(4) Remove belt from vehicle.
INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be routed correctly. If not, engine may
overheat due to water pump rotating in wrong
direction. Refer to (Fig. 10) or (Fig. 11)for correct
engine belt routing. The correct belt with correct
length must be used.
(1) Position drive belt over all pulleysexcept
water pump pulley.
(2) Attach a 1/2 inch ratchet to tensioner.
(3) Rotate ratchet and belt tensioner clockwise.
Place belt over water pump pulley. Let tensioner
rotate back into place. Remove ratchet. Be sure belt
is properly seated on all pulleys.
Fig. 10 Belt Routing ± 5.9L Diesel Engine With A/C
1 - GENERATOR PULLEY
2 - WATER PUMP PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT PULLEY
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR PUMP PULLEY
Fig. 11 Belt Routing - 5.9L Diesel Engine Without
A/C
1 - GENERATOR PULLEY
2 - WATER PUMP PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT PULLEY
7 - AUTOMATIC TENSIONER
DRACCESSORY DRIVE 7 - 29
DRIVE BELT - 5.9L DIESEL (Continued)

REMOVAL
3.7L V-6
The Engine Coolant Temperature (ECT) sensor on
the 3.7L engine is installed into a water jacket at
front of intake manifold near rear of generator (Fig.
10).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Partially drain the cooling system.
(2) Disconnect the electrical connector from the
sensor.
(3) Remove the sensor from the intake manifold.
4.7L V-8
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR.
The Engine Coolant Temperature (ECT) sensor on
the 4.7L V-8 engine is located near the front of the
intake manifold (Fig. 11).(1) Partially drain the cooling system. Refer to 7,
COOLING.
(2) Disconnect the electrical connector from the
ECT sensor.
(3) Remove the sensor from the intake manifold.
5.7L V-8
The Engine Coolant Temperature (ECT) sensor on
the 5.7L engine is located under the air conditioning
compressor (Fig. 12). It is installed into a water
jacket at the front of the cylinder block (Fig. 13).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Partially drain the cooling system.
(2) Remove fan belt. Refer to Accessory Drive in
Cooling section.
(3) Carefully unbolt air conditioning compressor
from front of engine. Do not disconnect any A/C hoses
from compressor. Temporarily support compressor to
gain access to ECT sensor. Refer to Heating and Air
Conditioning section for information.
(4) Disconnect electrical connector from sensor
(Fig. 13).
(5) Remove sensor from cylinder block.
Fig. 10 MAP SENSOR / ECT SENSOR - 3.7L V-6
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
4 - FRONT OF INTAKE MANIFOLD
Fig. 11 ECT SENSOR - 4.7L V-8
1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
3 - MAP SENSOR
4 - INTAKE MANIFOLD
DRENGINE 7 - 39
ENGINE COOLANT TEMPERATURE SENSOR (Continued)

DIAGNOSIS AND TESTINGÐTHERMOSTAT
ON-BOARD DIAGNOSTICS
Allgasoline powered modelsare equipped with
On-Board Diagnostics for certain cooling system com-
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor-
mation. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM mem-
ory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer to
the Diagnosis section of this group for other probable
causes.
The DTC can also be accessed through the
DRBIIItscan tool. Refer to the appropriate Power-
train Diagnostic Procedures information for diagnos-
tic information and operation of the DRBIIItscan
tool.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE COOLING SYSTEM HOT
AND PRESSURIZED. SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
Factory installed thermostat housings on 5.9L
engine is installed on a gasket with an anti-stick
coating. This will aid in gasket removal and clean-up.
(1) Disconnect the negative battery cable.
(2) Drain the cooling system until the coolant level
is below the thermostat (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Air Conditioned vehicles: Remove the support
bracket (generator mounting bracket-to-intake mani-
fold) located near the rear of the generator (Fig. 17).
NOTE: On air conditioning equipped vehicles, the
generator must be partially removed.
(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) (Fig. 18).
(5) Remove the generator mounting bolts. Do not
remove any of the wiring at the generator. If
equipped with 4WD, unplug the 4WD indicator lamp
wiring harness (located near rear of generator).
(6) Remove the generator. Position the generator
to gain access for the thermostat gasket removal.
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. 16 Thermostat - 5.7L/5.9L Gas Powered
Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
Fig. 17 Generator Support Bracket ± 5.9L Engine
1 - IDLER PULLEY BUSHING
2 - A/C AND/OR GENERATOR MOUNTING BRACKET
3 - IDLER PULLEY
4 - SCREW AND WASHER
7 - 42 ENGINEDR
ENGINE COOLANT THERMOSTAT- 5.7L (Continued)