Heat DODGE RAM 2001 Service Service Manual

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION...........................40
OPERATION.............................40
COOLANT RECOVERY CONTAINER - 3.9L/5.2L/
5.9L/5.9L DIESEL
DESCRIPTION...........................41
OPERATION.............................41
REMOVAL..............................41
INSTALLATION...........................41
COOLANT RECOVERY CONTAINER - 8.0L
DESCRIPTION...........................42
OPERATION.............................42
RADIATOR FAN - 3.9L/5.2L/5.9L/8.0L
REMOVAL..............................42
CLEANING..............................43
INSPECTION............................43
INSTALLATION...........................43
RADIATOR FAN - 5.9L DIESEL
REMOVAL..............................44
CLEANING..............................44
INSPECTION............................44
INSTALLATION...........................45
ENGINE BLOCK HEATER - 3.9L/5.2L/5.9L
DESCRIPTION...........................45
OPERATION.............................45
REMOVAL..............................45
INSTALLATION...........................45
ENGINE BLOCK HEATER - 8.0L
DESCRIPTION...........................46
OPERATION.............................46
REMOVAL..............................46
INSTALLATION...........................46
ENGINE BLOCK HEATER - 5.9L DIESEL
DESCRIPTION...........................47
OPERATION.............................47
REMOVAL..............................47
INSTALLATION...........................47
ENGINE COOLANT TEMP SENSOR - 3.9L/5.2L/
5.9L
DESCRIPTION...........................48
OPERATION.............................48
REMOVAL..............................48
INSTALLATION...........................48
ENGINE COOLANT THERMOSTAT - 3.9L/5.2L/
5.9L
DESCRIPTION...........................49
OPERATION.............................49
DIAGNOSIS AND TESTING.................49
THERMOSTAT.........................49REMOVAL..............................49
INSTALLATION...........................50
ENGINE COOLANT THERMOSTAT - 8.0L
DESCRIPTION...........................52
OPERATION.............................52
DIAGNOSIS AND TESTING.................52
THERMOSTAT.........................52
REMOVAL..............................52
INSTALLATION...........................53
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL
DESCRIPTION...........................54
OPERATION.............................54
DIAGNOSIS AND TESTING.................54
THERMOSTAT.........................54
REMOVAL..............................55
INSTALLATION...........................55
FAN DRIVE VISCOUS CLUTCH - 3.9L/5.2L/5.9L/
8.0L
DESCRIPTION...........................56
OPERATION.............................56
DIAGNOSIS AND TESTING.................56
VISCOUS FAN DRIVE...................56
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL
DESCRIPTION...........................57
OPERATION.............................57
DIAGNOSIS AND TESTING.................58
VISCOUS FAN DRIVE...................58
RADIATOR - 3.9L/5.2L/5.9L
DESCRIPTION...........................59
OPERATION.............................59
DIAGNOSIS AND TESTING.................59
RADIATOR COOLANT FLOW..............59
REMOVAL..............................59
CLEANING..............................60
INSPECTION............................61
INSTALLATION...........................61
RADIATOR - 8.0L
DESCRIPTION...........................61
OPERATION.............................61
DIAGNOSIS AND TESTING.................61
RADIATOR COOLANT FLOW..............61
REMOVAL..............................62
CLEANING..............................62
INSPECTION............................62
INSTALLATION...........................63
RADIATOR - 5.9L DIESEL
DESCRIPTION...........................63
OPERATION.............................63
BR/BEENGINE 7 - 39

DIAGNOSIS AND TESTING.................63
RADIATOR COOLANT FLOW..............63
REMOVAL..............................63
CLEANING..............................65
INSPECTION............................65
INSTALLATION...........................65
RADIATOR PRESSURE CAP
DESCRIPTION...........................65
OPERATION.............................65
DIAGNOSIS AND TESTING.................66
RADIATOR CAP-TO-FILLER NECK SEAL.....66
RADIATOR CAP........................66
CLEANING..............................66
INSPECTION............................66
WATER PUMP - 3.9L/5.2L/5.9L
DESCRIPTION...........................67
OPERATION.............................67
DIAGNOSIS AND TESTING.................67
WATER PUMP.........................67
REMOVAL..............................67
CLEANING..............................69INSPECTION............................69
INSTALLATION...........................70
WATER PUMP - 8.0L
DIAGNOSIS AND TESTING.................70
WATER PUMP.........................70
REMOVAL..............................70
CLEANING..............................72
INSPECTION............................72
INSTALLATION...........................72
WATER PUMP - 5.9L DIESEL
DESCRIPTION...........................73
OPERATION.............................73
DIAGNOSIS AND TESTING.................73
WATER PUMP.........................73
REMOVAL..............................73
CLEANING..............................73
INSPECTION............................73
INSTALLATION...........................74
WATER PUMP INLET TUBE - 3.9L/5.2L/5.9L
REMOVAL..............................74
INSTALLATION...........................77
COOLANT
DESCRIPTION
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti-
freeze concentrationmust alwaysbe a minimum of
44 percent, year-round in all climates.If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300) deg. F). This temperature is hot
enough to melt plastic and soften solder. Theincreased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at 22 deg. C (-8 deg. F ).
PROPYLENE-GLYCOL MIXTURES
It's overall effective temperature range is smaller
than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32 deg. C (-26 deg. F).
5 deg. C higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-
over) of propylene-glycol is 125 deg. C (257 deg. F )
at 96.5 kPa (14 psi), compared to 128 deg. C (263
deg. F) for ethylene-glycol. Use of propylene-glycol
can result in boil-over or freeze-up on a cooling sys-
tem designed for ethylene-glycol. Propylene glycol
also has poorer heat transfer characteristics than
ethylene glycol. This can increase cylinder head tem-
peratures under certain conditions.
Propylene-glycol/ethylene-glycol Mixtures can cause
the destabilization of various corrosion inhibitors,
causing damage to the various cooling system compo-
nents. Also, once ethylene-glycol and propylene-glycol
based coolants are mixed in the vehicle, conventional
methods of determining freeze point will not be accu-
rate. Both the refractive index and specific gravity dif-
fer between ethylene glycol and propylene glycol.
OPERATION
Coolant flows through the engine block absorbing the
heat from the engine, then flows to the radiator where
the cooling fins in the radiator transfers the heat from
the coolant to the atmosphere. During cold weather the
ethylene-glycol coolant prevents water present in the
cooling system from freezing within temperatures indi-
cated by mixture ratio of coolant to water.
7 - 40 ENGINEBR/BE

(6) Do not unbolt fan blade assembly (Fig. 6) from
viscous fan drive at this time.
(7) Remove four fan shroud-to-radiator mounting
bolts.
(8) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete unit from vehicle.(9) After removing fan blade/viscous fan drive
assembly,do notplace viscous fan drive in horizon-
tal position. If stored horizontally, silicone fluid in
the viscous fan drive could drain into its bearing
assembly and contaminate lubricant.
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under spring tension.
(10) Remove four bolts securing fan blade assem-
bly to viscous fan drive (Fig. 6).
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 6) to 23 N´m (17 ft. lbs.) torque.
(2) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(3) Install fan shroud.
Fig. 5 Using Special Tool 6958 Spanner Wrench
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2-FAN
Fig. 6 Fan Blade/Viscous Fan DriveÐGas EnginesÐ
Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
BR/BEENGINE 7 - 43
RADIATOR FAN - 3.9L/5.2L/5.9L/8.0L (Continued)

(4) Install fan blade/viscous fan drive assembly to
water pump shaft (Fig. 6).
(5) Except 8.0L V-10 Engine: Install coolant
reserve/overflow tank to fan shroud. Snaps into posi-
tion.
(6) Install throttle cable to fan shroud.
(7) Connect negative battery cable.
NOTE: Viscous Fan Drive Fluid Pump Out Require-
ment: After installing a new viscous fan drive, bring
the engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
RADIATOR FAN - 5.9L DIESEL
REMOVAL
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
(1) Disconnect the battery negative cables.
(2) Remove the fan shroud mounting bolts. Posi-
tion fan shroud towards engine.
CAUTION: Do not remove the fan pulley bolts. This
pulley is under spring tension.
(3) The thermal viscous fan drive/fan blade assem-
bly is attached (threaded) to the fan hub shaft (Fig.
7). Remove the fan blade/fan drive assembly from fan
pulley by turning the mounting nut clockwise (as
viewed from front). Threads on the viscous fan drive
areLEFT-HAND.A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between the fan pulley bolts to prevent
pulley from rotating.
(4) Remove the fan shroud and the fan blade/vis-
cous drive as an assembly from vehicle.
(5) Remove fan blade-to-viscous fan drive mount-
ing bolts.
(6) Inspect the fan for cracks, loose rivets, loose or
bent fan blades.
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the wordREVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
Fig. 7 Fan Blade/Viscous Fan Drive
1 - THREADED SHAFT
2 - BOLT (4)
3 - FAN BLADE
4 - THREADED NUT
5 - VISCOUS FAN DRIVE
7 - 44 ENGINEBR/BE
RADIATOR FAN - 3.9L/5.2L/5.9L/8.0L (Continued)

(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten mounting bolts to 23 N´m (17 ft. lbs.) torque.
(2) Position the fan shroud and fan blade/viscous
fan drive to the vehicle as an assembly.
(3) Install viscous fan drive assembly on fan hub
shaft (Fig. 7). Tighten mounting nut to 57 N´m (42 ft.
lbs.) torque.
(4) Install fan shroud bolts into position and
tighten the mounting bolts to 6 N´m (50 in. lbs.)
torque.
(5) Connect the battery negative cables.
NOTE: Viscous Fan Drive Fluid Pump Out Require-
ment: After installing a new viscous fan drive, bring
the engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
ENGINE BLOCK HEATER -
3.9L/5.2L/5.9L
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An optional engine block heater is available on all
models. The heater is equipped with a power cord.
The heater is mounted in a core hole of the engine
cylinder block (in place of a freeze plug) with the
heating element immersed in engine coolant. The
cord is attached to an engine compartment compo-
nent with tie-straps.
The 3.9L and 5.9L gas powered engine has the
block heater located on the right side of engine next
to the oil filter (Fig. 8).
OPERATION
The heater warms the engine coolant providing
easier engine starting and faster warm-up in low
temperatures. Connecting the power cord to a
grounded 110-120 volt AC electrical outlet with a
grounded three wire extension cord provides the elec-
tricity needed to heat the element..
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(3) Remove power cord from heater by unplugging
(Fig. 9).
(4) Loosen (but do not completely remove) the
screw at center of block heater (Fig. 9).
(5) Remove block heater by carefully prying from
side-to-side. Note direction of heating element coil
(up or down). Element coil must be installed correctly
to prevent damage.
INSTALLATION
(1) Clean and inspect the block heater hole.
(2) Install new O-ring seal(s) to heater in gasoline
engines.
(3) Insert block heater into cylinder block.
(4) With heater fully seated, tighten center screw
to 2 N´m (17 in. lbs.).
(5) Fill cooling system with recommended coolant.
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(6) Start and warm the engine.
(7) Check block heater for leaks.
Fig. 8 Engine Block Heater
1 - FREEZE PLUG HOLE
2 - BLOCK HEATER
3 - SCREW
4 - POWER CORD (120V AC)
5 - HEATING COIL
6 - OIL FILTER
BR/BEENGINE 7 - 45
RADIATOR FAN - 5.9L DIESEL (Continued)

ENGINE BLOCK HEATER - 8.0L
DESCRIPTION
An optional engine block heater is available on all
models. The heater is equipped with a power cord.
The heater is mounted in a core hole of the engine
cylinder block (in place of a freeze plug) with the
heating element immersed in engine coolant. The
cord is attached to an engine compartment compo-
nent with tie-straps.
The 8.0L V-10 engine has the block heater located
on the right side of engine next to the engine oil dip-
stick tube (Fig. 10).
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
OPERATION
The heater warms the engine coolant providing
easier engine starting and faster warm-up in low
temperatures. Connecting the power cord to agrounded 110-120 volt AC electrical outlet with a
grounded three wire extension cord provides the elec-
tricity needed to heat the element..
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain coolant from radiator and cylinder block
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(3) Remove power cord from heater by unplugging
(Fig. 11).
(4) Loosen (but do not completely remove) the
screw at center of block heater (Fig. 11).
(5) Remove block heater by carefully prying from
side-to-side. Note direction of heating element coil
(up or down). Element coil must be installed correctly
to prevent damage.
INSTALLATION
(1) Clean and inspect the block heater hole.
(2) Install new O-ring seal(s) to heater in gasoline
engines.
(3) Insert block heater into cylinder block.
(4) With heater fully seated, tighten center screw
to 2 N´m (17 in. lbs.).
Fig. 9 Engine Block Heater
1 - FREEZE PLUG HOLE
2 - BLOCK HEATER
3 - SCREW
4 - POWER CORD (120V AC)
5 - HEATING COIL
6 - OIL FILTER
Fig. 10 Engine Block HeaterÐ8.0L V-10 Engine
1 - FREEZE PLUG HOLE
2 - SCREW
3 - POWER CORD (120V AC)
4 - BLOCK HEATER
5 - HEATING COIL
7 - 46 ENGINEBR/BE
ENGINE BLOCK HEATER - 3.9L/5.2L/5.9L (Continued)

(5) Fill cooling system with recommended coolant
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(6) Start and warm the engine.
(7) Check block heater for leaks.
ENGINE BLOCK HEATER - 5.9L
DIESEL
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An optional engine block heater is available on all
models. The heater is equipped with a power cord.
The heater is mounted in a core hole of the engine
cylinder block (in place of a freeze plug) with the
heating element immersed in engine coolant. The
cord is attached to an engine compartment compo-
nent with tie-straps.The 5.9L diesel engine has the block heater located
on the right side of the engine below the exhaust
manifold next to the oil cooler (Fig. 12).
OPERATION
The heater warms the engine coolant providing
easier engine starting and faster warm-up in low
temperatures. Connecting the power cord to a
grounded 110-120 volt AC electrical outlet with a
grounded three wire extension cord provides the elec-
tricity needed to heat the element..
REMOVAL
(1) Disconnect the battery negative cables.
(2) Drain coolant from radiator and cylinder block
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(3) Unscrew the power cord retaining cap and dis-
connect cord from heater element.
(4) Using a suitable size socket, loosen and remove
the block heater element (Fig. 13).
INSTALLATION
(1) Clean and inspect the threads in the cylinder
block.
(2) Coat heater element threads with Mopart
Thread Sealer with Teflon.
(3) Screw block heater into cylinder block and
tighten to 43 N´m (32 ft. lbs.).
(4) Connect block heater cord and tighten retain-
ing cap.
(5) Fill cooling system with recommended coolant
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(6) Start and warm the engine.
(7) Check block heater for leaks.
Fig. 11 Block HeaterÐ8.0L V-10 Engine
1 - FREEZE PLUG HOLE
2 - SCREW
3 - POWER CORD (120V AC)
4 - BLOCK HEATER
5 - HEATING COIL
Fig. 12 Engine Block HeaterÐ5.9L Diesel Engine
1 - BLOCK HEATER
BR/BEENGINE 7 - 47
ENGINE BLOCK HEATER - 8.0L (Continued)

ENGINE COOLANT TEMP
SENSOR - 3.9L/5.2L/5.9L
DESCRIPTION
The Engine Coolant Temperature (ECT) sensor is
used to sense engine coolant temperature. The sensor
protrudes into an engine water jacket.
The ECT sensor is a two-wire Negative Thermal
Coefficient (NTC) sensor. Meaning, as engine coolant
temperature increases, resistance (voltage) in the
sensor decreases. As temperature decreases, resis-
tance (voltage) in the sensor increases.
OPERATION
At key-on, the Powertrain Control Module (PCM)
sends out a regulated 5 volt signal to the ECT sensor.
The PCM then monitors the signal as it passes
through the ECT sensor to the sensor ground (sensor
return).
When the engine is cold, the PCM will operate in
Open Loop cycle. It will demand slightly richer air-
fuel mixtures and higher idle speeds. This is done
until normal operating temperatures are reached.
The PCM uses inputs from the ECT sensor for the
following calculations:
²for engine coolant temperature gauge operation
through CCD or PCI (J1850) communications
²Injector pulse-width
²Spark-advance curves
²ASD relay shut-down times
²Idle Air Control (IAC) motor key-on steps
²Pulse-width prime-shot during cranking
²O2 sensor closed loop times
²Purge solenoid on/off times
²EGR solenoid on/off times (if equipped)
²Leak Detection Pump operation (if equipped)²Radiator fan relay on/off times (if equipped)
²Target idle speed
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Partially drain cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(2) Remove air cleaner assembly.
(3) Disconnect electrical connector from sensor
(Fig. 14).
(4)Engines with air conditioning:When
removing the connector from sensor, do not pull
directly on wiring harness. Fabricate an L-shaped
hook tool from a coat hanger (approximately eight
inches long). Place the hook part of tool under the
connector for removal. The connector is snapped onto
the sensor. It is not equipped with a lock type tab.
(5) Remove sensor from intake manifold.
INSTALLATION
(1) Install sensor.
(2) Tighten to 6±8 N´m (55±75 in. lbs.) torque.
(3) Connect electrical connector to sensor. The sen-
sor connector is symmetrical (not indexed). It can be
installed to the sensor in either direction.
(4) Install air cleaner assembly.
(5) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Fig. 13 Block HeaterÐDiesel Engine
1 - BLOCK HEATER
Fig. 14 Engine Coolant Temperature
1 - GENERATOR
2 - A/C COMPRESSOR
3 - ENGINE COOLANT TEMPERATURE SENSOR
4 - ELEC. CONN.
7 - 48 ENGINEBR/BE
ENGINE BLOCK HEATER - 5.9L DIESEL (Continued)

ENGINE COOLANT
THERMOSTAT - 3.9L/5.2L/5.9L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on the 3.9L, 5.2L and 5.9L gas
powered engines is located beneath the thermostat
housing at the front of the intake manifold (Fig. 15).
The thermostat is a wax pellet driven, reverse pop-
pet choke type.
Coolant leakage into the pellet container will cause
the thermostat to fail in the open position. Thermo-
stats very rarely stick. Do not attempt to free a ther-
mostat with a prying device.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance,
increased exhaust emissions and crankcase condensa-
tion that can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
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. For other DTC numbers, (Refer to 25 - EMIS-
SIONS CONTROL - DESCRIPTION).
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures information for diagnostic informa-
tion and operation of the DRB scan tool.
REMOVAL
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
Factory installed thermostat housings on 3.9L,
5.2L and 5.9L engines are installed on a gasket with
an anti-stick coating. This will aid in gasket removal
and clean-up.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(3) Air Conditioned vehicles: Remove support
bracket (generator mounting bracket-to-intake mani-
fold) located near rear of generator (Fig. 16).
NOTE: On air conditioning equipped vehicles, the
generator must be partially removed.
Fig. 15 ThermostatÐ5.2L and 5.9L Gas Powered
Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
BR/BEENGINE 7 - 49

(4) Position thermostat housing to intake manifold.
Note the word FRONT stamped on housing (Fig. 20).
For adequate clearance, thismustbe placed towards
front of vehicle. The housing is slightly angled for-
ward after installation to intake manifold.
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 N´m (200 in. lbs.) torque.
(6) Install radiator upper hose to thermostat hous-
ing.
CAUTION: When installing the serpentine 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. 21) for correct 3.9L,
5.2L and 5.9L engine belt routing. The correct belt
with correct length must be used.
(7) Air Conditioned vehicles; Install generator.
Tighten bolts to 41 N´m (30 ft. lbs.).
(8) Install support bracket (generator mounting
bracket-to-intake manifold) (Fig. 16). Tighten bolts to
54 N´m (40 ft. lbs.) torque.
(9) Install accessory drive belt (Fig. 17)(Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect battery negative cable.(12) Start and warm the engine. Check for leaks.
Fig. 19 ThermostatÐ3.9L and 5.9L Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVEFig. 20 Thermostat PositionÐ5.2L and 5.9L Engines
Fig. 21 Belt RoutingÐ5.2L and 5.9L Engines
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - A/C COMPRESSOR PULLEY
4 - IF W/OUT A/C
5 - POWER STEERING PUMP PULLEY
6 - WATER PUMP PULLEY
7 - CRANKSHAFT PULLEY
8 - AUTOMATIC TENSIONER
BR/BEENGINE 7 - 51
ENGINE COOLANT THERMOSTAT - 3.9L/5.2L/5.9L (Continued)