power DODGE RAM 2002 Service Service Manual

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
BR/BEENGINE 7 - 45
ENGINE BLOCK HEATER - 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 threaded hole of the
engine cylinder block with the heating element
immersed in engine coolant. The cord is attached to
an engine compartment component 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
7 - 46 ENGINEBR/BE
ENGINE BLOCK HEATER - 8.0L (Continued)

ENGINE COOLANT TEMP
SENSOR - 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.
BR/BEENGINE 7 - 47
ENGINE BLOCK HEATER - 5.9L DIESEL (Continued)

ENGINE COOLANT
THERMOSTAT - 5.9L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on the 5.9L gas powered engine 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, thepellet 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.
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) (Fig. 17).
(5) Remove two generator mounting bolts. Do not
remove any wiring at generator. If equipped with
4WD, unplug 4WD indicator lamp wiring harness
(located near rear of generator).
Fig. 15 Thermostat - 5.9L Gas Powered Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
7 - 48 ENGINEBR/BE

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 ThermostatÐ5.9L Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
Fig. 20 Thermostat PositionÐ5.9L Engines
Fig. 21 Belt RoutingÐ5.9L 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
7 - 50 ENGINEBR/BE
ENGINE COOLANT THERMOSTAT - 5.9L (Continued)

ENGINE COOLANT
THERMOSTAT - 8.0L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on all gas powered engines is
located beneath the thermostat housing at the front
of the intake manifold (Fig. 22).
The thermostat is a moveable sleeve 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 THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-SURIZED. 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.
A rubber lip-type seal with a metal shoulder is
pressed into the intake manifold beneath the thermo-
stat (Fig. 23).
(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) Remove the two support rod mounting bolts
and remove support rod (intake manifold-to-genera-
tor mount) (Fig. 24).
Fig. 22 ThermostatÐ8.0L V-10 Engine
1 - COOLANT TEMP. SENSOR (FOR PCM)
2 - HEATER SUPPLY FITTING
3 - BOLTS (6)
4 - HOUSING WITH INTEGRAL SEAL
5 - THERMOSTAT
6 - RUBBER LIP SEAL
7 - TEMP. GAUGE SENDING UNIT
BR/BEENGINE 7 - 51

(4) Install thermostat into recessed machined
groove on intake manifold (Fig. 25).
(5) Install thermostat housing (Fig. 25).
(6) Install housing-to-intake manifold bolts.
Tighten bolts to 25 N´m (220 in. lbs.) torque.
CAUTION: Housing bolts should be tightened
evenly to prevent damage to housing and to pre-
vent leaks.
(7) Connect the wiring to both sensors.
(8) Install the upper radiator hose and hose clamp
to thermostat housing.
(9) Install support rod.
(10) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect negative battery cable to battery.
(12) Start and warm engine. Check for leaks.
ENGINE COOLANT
THERMOSTAT - 5.9L DIESEL
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing. An engine
with the thermostat removed will operate in the
radiator bypass mode, causing an overheat condi-
tion.
The thermostat of the 5.9L diesel engine is located
in the front of the cylinder head, underneath the
water outlet connector (Fig. 26).
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
The cooling system used with the diesel engine
provides the extra coolant capacity and extra cooling
protection needed for higher GVWR (Gross Vehicle
Weight Rating) and GCWR (Gross Combined Weight
Rating) vehicles.
This system capacity will not effect warm up or
cold weather operating characteristics if the thermo-stat is operating properly. This is because coolant
will be held in the engine until it reaches the ther-
mostat ªsetº temperature.
Diesel engines, due to their inherent efficiency are
slower to warm up than gasoline powered engines,
and will operate at lower temperatures when the
vehicle is unloaded. Because of this, lower tempera-
ture gauge readings for diesel versus gasoline
engines may, at times be normal.
Typically, complaints of low engine coolant temper-
ature are observed as low heater output when com-
bined with cool or cold outside temperatures.
To help promote faster engine warm-up, the elec-
tric engine block heater must be used with cool or
cold outside temperatures. This will help keep the
engine coolant warm when the vehicle is parked. Use
the block heater if the outside temperature is below
4ÉC (40ÉF).Do not use the block heater if the
outside temperature is above 4ÉC (40ÉF).
A ªCold Weather Coverº is available from the parts
department through the Mopar Accessories product
line. This accessory cover is designed to block airflow
entering the radiator and engine compartment to
promote faster engine warm-up. It attaches to the
front of the vehicle at the grill opening.The cover is
to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result.Refer to the litera-
ture supplied with the cover for additional informa-
tion.
Fig. 26 ThermostatÐ5.9L DieselÐTypical
1 - WATER OUTLET CONNECTOR
2 - THERMOSTAT HOUSING
3 - THERMOSTAT
BR/BEENGINE 7 - 53
ENGINE COOLANT THERMOSTAT - 8.0L (Continued)

INSPECTION
Hold cap at eye level, right side up. The vent valve
(Fig. 45) at bottom of cap should open. If rubber gas-
ket has swollen and prevents vent valve from open-
ing, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket,
replace cap.Do not use a replacement cap that
has a spring to hold vent shut.A replacement cap
must be the type designed for a coolant reserve/over-
flow system with a completely sealed diaphragm
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.
WATER PUMP - 5.9L
DESCRIPTION
The water pump is located on the engine front
cover, and has an integral pulley attached (Fig. 46).
The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ven-
tilation. The water pump seals are lubricated by
antifreeze in the coolant mixture. Additional lubrica-
tion is not necessary.
OPERATION
A centrifugal water pump circulates coolant
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core,this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.
DIAGNOSIS AND TESTINGÐWATER PUMP
A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
REMOVAL
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover.
On the 5.9L gas powered engine, a gasket is used
as a seal between the water pump and timing chain
case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for
fatigue cracks, loose blades or loose rivets that could
have resulted from excessive vibration. Replace fan if
any of these conditions are found. Also check condi-
tion of the thermal viscous fan drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - DIAGNOSIS AND TESTING).
(1) Disconnect negative cable from battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
Fig. 45 Radiator Pressure Cap
1 - STAINLESS-STEEL SWIVEL TOP
2 - RUBBER SEALS
3 - VENT VALVE
4 - RADIATOR TANK
5 - FILLER NECK
6 - OVERFLOW NIPPLE
7 - MAIN SPRING
8 - GASKET RETAINER
Fig. 46 Water Pump LocationÐTypical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
7 - 66 ENGINEBR/BE
RADIATOR PRESSURE CAP (Continued)

(2) Using a new gasket, install water pump to
engine as follows: Guide water pump nipple into
bypass hose as pump is being installed. Install water
pump bolts (Fig. 52). Tighten water pump mounting
bolts to 40 N´m (30 ft. lbs.) torque.
(3) Position bypass hose clamp to bypass hose.
(4) Spin water pump to be sure that pump impel-
ler does not rub against timing chain case/cover.
(5) Install a new o-ring to the heater hose coolant
return tube (Fig. 51). Coat the new o-ring with anti-
freeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Fig. 51). Be sure the slot in tube
bracket is bottomed to mounting bolt. This will prop-
erly position return tube.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to coolant
return tube.
(9) Install drive belt (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLATION)
(Fig. 50).
(10) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(11) Install fan shroud.
(12) Install fan blade/viscous fan drive assembly to
water pump shaft.
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect negative battery cable.
(15) Start and warm the engine. Check for leaks.
WATER PUMP - 8.0L
DIAGNOSIS AND TESTINGÐWATER PUMP
A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
REMOVAL
NOTE:
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/
cover.
On the 8.0L V-10 engine, a rubber o-ring (instead of
a gasket) is used as a seal between the water pump
and timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for
fatigue cracks, loose blades or loose rivets that couldhave resulted from excessive vibration. Replace fan if
any of these conditions are found. Also check condi-
tion of the thermal viscous fan drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - DIAGNOSIS AND TESTING).
(1) Disconnect negative battery cable from battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) Remove windshield washer reservoir tank from
radiator fan shroud.
(4) Remove the four fan shroud mounting bolts at
the radiator (Fig. 53). Do not attempt to remove
shroud from vehicle at this time.
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, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(5) Remove radiator upper hose at radiator.
(6) The thermal viscous fan drive is attached
(threaded) to the water pump hub shaft (Fig. 55).
Fig. 53 Typical Fan Shroud Mounting
1 - RADIATOR SUPPORT
2 - RADIATOR
3 - BOLTS (4)
4 - FAN SHROUD
BR/BEENGINE 7 - 69
WATER PUMP - 5.9L (Continued)

(15) Lift and position generator and A/C compres-
sor (along with their common mounting bracket) to
gain access to bypass hose. A block of wood may be
used to hold assembly in position.
(16) Loosen and position both hose clamps to the
center of bypass hose. A special clamp tool must be
used to remove the constant tension clamps. Remove
hose from vehicle.
REMOVAL - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
A water pump bypass hose (Fig. 70) is used
between the intake manifold and water pump on all
gas powered engines. To test for leaks, (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
(1) Partially drain cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE). Do not
waste reusable coolant. If the solution is clean, drain
the coolant into a clean container for reuse.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, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYS
WEAR SAFETY GLASSES WHEN SERVICING CON-
STANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with a matching number or letter.
(2) Loosen both bypass hose clamps and position to
the center of hose.
(3) Remove hose from vehicle.
INSTALLATION
INSTALLATION - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING
(1) Position bypass hose clamps to the center of
hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Install generator-A/C mounting bracket assem-
bly to engine. Tighten bolt number 1 (Fig. 63) to 41
N´m (30 ft. lbs.) torque. Tighten bolt number 2 (Fig.
63) to 28 N´m (20 ft. lbs.) torque. Tighten bracket
mounting bolts (Fig. 68) (Fig. 69) to 40 N´m (30 ft.
lbs.) torque.
(5) Install a new O-ring to the heater hose coolant
return tube (Fig. 66) (Fig. 67). Coat the new O-ring
with antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Fig. 66) (Fig. 67).
(7) Connect throttle body control cables.
(8) Install oil dipstick mounting bolt.
(9)/5.9L V-8 LDC-Gas Engine:Install idler pul-
ley. Tighten bolt to 41 N´m (30 ft. lbs.) torque.
Fig. 70 Water Pump Bypass Hose - Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
7 - 76 ENGINEBR/BE
WATER PUMP INLET TUBE - 5.9L (Continued)