tow DODGE RAM 2003 Service Owner's Manual

(9) Subtract each reading from the one 180É oppo-
site to determine runout and direction. Bore runout
example (Fig. 10):
²0.000 ± (±0.007) = 0.007 in.
²+0.002 ± (±0.010) = 0.012 in.
²+0.004 ± (±0.005) = 0.009 in.
²±0.001 ± (+0.001) = ±0.002 in.
In this example the largest or total indicator read-
ing (TIR) difference is 0.012 inch. This means the
housing bore is offset from the crankshaft centerline
by 0.006 in. which is 1/2 of 0.012 inch. The dowels
needed to correct this have an offset of 0.007 in. (Fig.
11).
Remove housing and install dowels with the slotted
side facing out so they can be turned with a screw-driver. Then install the housing and mount the dial
indicator and check bore runout again. Rotate the
dowels until the TIR is less than 0.010 inch.
Clutch Housing Face Runout
(1) Position dial indicator towards the housing face
(Fig. 12) with indicator plunger on the rim of the
housing bore.
(2) Rotate crankshaft until indicator plunger is at
the 10 O'clock position and zero the dial indicator.
(3) Measure and record face runout readings at
four points 90É apart (Fig. 13). Take measurement at
least twice for accuracy.
(4) Subtract lowest reading from highest to deter-
mine total runout. If low reading wasminus0.004
in. and highest reading wasplus0.009 in. the total
runout is 0.013 inch.
Fig. 10 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING BORE CIRCLE
Fig. 11 ALIGNMENT DOWEL SELECTION
1 - SLOT DIRECTION OF OFFSET
2 - OFFSET DOWEL
TIR VALUE OFFSET DOWEL REQUIRED
0.011 - 0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
Fig. 12 DIAL INDICATOR LOCATION
1 - INDICATOR PLUNGER
2 - DIAL INDICATOR
3 - CLUTCH HOUSING FACE
4 - INDICATOR MOUNTING STUD OR ROD
Fig. 13 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING FACE CIRCLE (AT RIM OF BORE)
DRCLUTCH 6 - 9
CLUTCH HOUSING (Continued)

(6) Install the clutch housing dust shield to the
clutch housing.
(7) Install transmission and transfer case, if
equipped.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmission and transfer case, if
equipped.
(2) Remove spring clip.
(3) Disconnect release bearing from release fork
and remove bearing (Fig. 17).
INSTALLATION
(1) Inspect bearing slide surface on transmission
front bearing retainer. Replace retainer if slide sur-
face is scored, worn, or cracked.
(2) Inspect release lever and pivot stud. Be sure
stud is secure and in good condition. Be sure fork is
not distorted or worn. Replace fork spring clips if
bent or damaged.
(3) Lubricate input shaft splines, bearing retainer
slide surface, lever pivot ball stud, and release lever
pivot surface with Moparthigh temperature bearing
grease.
(4) Install release fork and release bearing (Fig.
18). Be sure fork and bearing are properly secured by
spring clips. Also be sure that the release fork is
installed properly. The rear side of the release lever
has one end with a raised area. This raised area goes
toward the slave cylinder side of the transmission.
(5) Install clutch housing, if removed.(6) Install transmission and transfer case.
(7) Check clutch master cylinder fluid level.
FLYWHEEL
DIAGNOSIS AND TESTING
Check flywheel runout whenever misalignment is
suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
the flywheel face with a dial indicator. Mount the
indicator on a stud installed in place of one of the fly-
wheel bolts.
Common causes of runout are:
²heat warpage
²improper machining
²incorrect bolt tightening
²improper seating on crankshaft flange shoulder
²foreign material on crankshaft flange
Flywheel machining is not recommended. The fly-
wheel clutch surface is machined to a unique contour
and machining will negate this feature. Minor fly-
wheel scoring can be cleaned up by hand with 180
grit emery or with surface grinding equipment.
Remove only enough material to reduce scoring
(approximately 0.001 - 0.003 in.). Heavy stock
removal isnot recommended.Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
in.). Excessive stock removal can result in flywheel
cracking or warpage after installation; it can also
weaken the flywheel and interfere with proper clutch
release.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout. Use new
Fig. 17 CLUTCH RELEASE COMPONENTS
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 N´m (200 IN. LBS.)
6 - SPRING CLIP
Fig. 18 Clutch Release Fork And
1 - PIVOT BALL
2 - FORK
3 - SLAVE CYLINDER OPENING
4 - BEARING
DRCLUTCH 6 - 11
CLUTCH HOUSING (Continued)

bolts when remounting a flywheel and secure the
bolts with Mopar Lock And Seal or equivalent.
Tighten flywheel bolts to specified torque only. Over-
tightening can distort the flywheel hub causing
runout.
REMOVAL
(1) Remove transmission.
(2) Remove pressure plate and clutch.
(3) Remove flywheel bolts and remove flywheel.
DISASSEMBLY
NOTE: If the teeth are worn or damaged, the fly-
wheel should be replaced as an assembly. This is
the recommended repair. In cases where a new fly-
wheel is not readily available, (V10/Diesel Engine
only) a replacement ring gear can be installed. The
following procedure must be observed to avoid
damaging the flywheel and replacement gear.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES WHILE CUTTING RING GEAR.
(1) Mark position of the old gear for alignment ref-
erence on the flywheel. Use a scriber for this pur-
pose.
(2) Remove the old gear by cutting most of the way
through it (at one point) with an abrasive cut-off
wheel. Then complete removal with a cold chisel or
punch.
ASSEMBLY
NOTE: The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
in order to install it. The method of heating and
expanding the gear is extremely important. Every
surface of the gear must be heated at the same
time to produce uniform expansion. An oven or
similar enclosed heating device must be used. Tem-
perature required for uniform expansion is approxi-
mately 375É F.
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES AND HEAT RESISTENT GLOVES
WHEN HANDLING A HEATED RING GEAR.
(1) The heated gear must be installed evenly to
avoid misalignment or distortion.
(2) Position and install the heated ring gear on the
flywheel with a shop press and a suitable press
plates.
(3) Place flywheel on work bench and let it cool in
normal shop air. Allow the ring gear to cool down
completely before installation it on the engine.
CAUTION: Do not use water or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air will distort or crack the
new gear.
INSTALLATION
(1) Install flywheel on the crank shaft.
(2) Install flywheel bolts and tighten to 95 N´m (70
ft. lbs.).
(3) Install clutch.
(4) Install transmission.
PILOT BEARING
REMOVAL
(1) Remove transmission.
(2) Remove clutch disc.
(3) Use a suitable blind hole puller to remove pilot
bearing.
INSTALLATION
(1) Clean bearing bore with solvent and wipe dry
with shop towel.
(2) Install new bearing with clutch alignment tool
(Fig. 19). Drive bearing into place with the letter side
of the bearing facing the transmission. Bearing
should be flush with edge of bearing bore.
CAUTION: Do not allow bearing to become cocked
and do not recess bearing.
6 - 12 CLUTCHDR
FLYWHEEL (Continued)

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3.7L/4.7L ENGINE......................1
DESCRIPTION - COOLING SYSTEM FLOW -
5.9L ENGINE..........................1
DESCRIPTIONÐCOOLING SYSTEM FLOW -
5.9L DIESEL..........................2
DESCRIPTION - HOSE CLAMPS...........3
OPERATION
OPERATIONÐCOOLING SYSTEM.........3
OPERATIONÐHOSE CLAMPS............5
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)...................5
DIAGNOSIS AND TESTINGÐCOOLING
SYSTEM - TESTING FOR LEAKS..........5
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIESEL ENGINE................7
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS............................10
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
LEVEL CHECK........................17STANDARD PROCEDURE - COOLING
SYSTEM CLEANING/REVERSE FLUSHING . . 17
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE . . 18
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE . . 18
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 5.9L/8.0L ENGINE......18
STANDARD PROCEDUREÐREFILLING
COOLING SYSTEM 5.9L/8.0L ENGINE......18
STANDARD PROCEDUREÐDRAINING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
STANDARD PROCEDUREÐREFILLING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................19
SPECIFICATIONS
TORQUE............................20
SPECIFICATIONS -....................20
SPECIAL TOOLS
COOLING...........................20
ACCESSORY DRIVE......................22
ENGINE...............................35
TRANSMISSION.........................72
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3.7L/4.7L ENGINE
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system provides a means of heating
the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant through the system and a
coolant deaeration and reserve system that utilizes a
pressurized degas bottle (hot bottle).
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity forvehicles used under extreme conditions such as
trailer towing in high ambient temperatures (Fig. 1).
DESCRIPTION - COOLING SYSTEM FLOW -
5.9L ENGINE
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system uses a coolant recovery / reserve system that
utilizes an ambient overflow bottle.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures (Fig. 2).
DRCOOLING 7 - 1

system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
5.9L, 5.9L Diesel, and 8.0L engines utilize an
ambient overflow bottle for coolant recovery/reserve.
The 3.7L and 4.7L engines utilize a pressurized
degas bottle for coolant deaeration and reserve. This
degas bottle has coolant flowing through it continu-
ously, supplied by a vent in the hot side radiator
tank and returning to the heater return hose.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.
OPERATIONÐHOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Engine Control Module (ECM) has been pro-
grammed to monitor certain cooling system compo-
nents:
²If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) can be set.²If an open or shorted condition has developed in
the electronically controlled viscous fan clutch circuit,
a Diagnostic Trouble Code (DTC) can be set.
²If fan speed is not detected a DTC will be set.
²Coolant temperature sensor circuit problems can
set a DTC.
If the problem is sensed in a monitored circuit
often enough to indicated an actual problem, a DTC
is stored. The DTC will be stored in the ECM mem-
ory for eventual display to the service technician.
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTC's and to obtain cooling system data,
(Refer to 25 - EMISSIONS CONTROL - DESCRIP-
TION).
ERASING TROUBLE CODES
After the problem has been repaired, use the
DRBIIItscan tool to erase a DTC. Refer to the
appropriate Powertrain Diagnostic Procedures ser-
vice information for operation of the DRBIIItscan
tool.
DIAGNOSIS AND TESTINGÐCOOLING SYSTEM
- TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available through the
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate the engine until the radi-
ator upper hose is warm to the touch. Aim the com-
mercially available black light tool at the components
to be checked. If leaks are present, the black light
will cause the additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 5).
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
ature. Recheck the system cold if the cause of coolant
loss is not located during the warm engine examina-
tion.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove the radiator pressure cap from
the filler neck and check the coolant level. Push
down on the cap to disengage it from the stop tabs.
Wipe the inside of the filler neck and examine the
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
DRCOOLING 7 - 5
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)1. Radiator and/or A/C condenser
air flow obstructed.1. Remove obstruction and/or clean.
2. Electronically controlled viscous
fan drive not working.2. Check fan drive. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
3. Air seals around radiator
damaged or missing.3. Inspect air seals, repair or
replace as necessary.
INADEQUATE HEATER
PERFORMANCE. GAUGE MAY OR
MAY NOT READ LOW.1. Heavy duty cooling system, and
cooler ambient temperatures.1. None. Normal condition.
2. Obstruction in heater hoses. 2. Remove hoses, remove
obstruction.
3. Electronically controlled viscous
fan stuck onCheck fan drive. (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
4. Water pump damaged. 4. Replace water pump.
HEAT ODOR 1. Damaged or missing drive line
heat shields.1. Repair or replace damaged or
missing heat shields.
2. Electronically controlled viscous
fan drive damaged.2. Check thermal viscous fan drive.
(Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DIAGNOSIS AND TESTING)
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
²PROLONGED IDLE
²VERY HIGH AMBIENT TEMPERATURE
²SLIGHT TAIL WIND AT IDLE
²SLOW TRAFFIC
²TRAFFIC JAMS
²HIGH SPEED OR STEEP GRADES
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.
TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect the cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts. Incorrect water pump or pump
rotating in wrong direction due to belt not correctly
routed
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
²Service to electrically controlled viscous fan
clutch
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to COOLING SYSTEM DIAGNOSIS
CHART BELOW.
These charts are to be used as a quick-reference
only. Refer to COOLING SYSTEM DIAGNOSIS
CHART
7 - 10 COOLINGDR
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS HIGH OR THE
COOLANT WARNING LAMP
ILLUMINATES. COOLANT MAY
OR MAY NOT BE LOST OR
LEAKING FROM THE COOLING
SYSTEM1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic,
or engine is being idled with
very high ambient (outside)
temperatures and the air
conditioning is on. Higher
altitudes could aggravate these
conditions.1. This may be a temporary condition and
repair is not necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to the
normal range. If the gauge does not return
to the normal range, determine the cause
for overheating and repair. Refer to
Possible Causes (2-18).
2. Is the temperature gauge
reading correctly?2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL). Repair as
necessary.
3. Is the temperature warning
illuminating unnecessarily?3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - SCHEMATIC -
ELECTRICAL).
4. Coolant low in coolant
reserve/overflow tank and
radiator?4. Check for coolant leaks and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
5. Pressure cap not installed
tightly. If cap is loose, boiling
point of coolant will be lowered.
Also refer to the following Step
6.5. Tighten cap
6. Poor seals at the radiator
cap.6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace cap
if necessary.
(b) Check condition of radiator filler neck.
If neck is bent or damaged, replace
radiator (5.9L) or degas bottle (3.7L, 4.7L).
7. Coolant level low in radiator
but not in coolant reserve/
overflow tank. This means the
radiator is not drawing coolant
from the coolant reserve/
overflow tank as the engine
cools (5.9L).7. (a) Check condition of radiator cap and
cap seals. Refer to Radiator Cap in this
Group. Replace cap if necessary.
(b) Check condition of radiator filler neck.
If neck is bent or damaged, replace
radiator.
(c) Check condition of the hose from the
radiator to the coolant tank. It should fit
tight at both ends without any kinks or
tears. Replace hose if necessary.
(d) Check coolant reserve/overflow tank
and tanks hoses for blockage. Repair as
necessary.
8. Incorrect coolant
concentration8. Check coolant. (Refer to LUBRICATION
& MAINTENANCE/FLUID TYPES -
DESCRIPTION).
9. Coolant not flowing through
system9. Check for coolant flow at radiator filler
neck with some coolant removed, engine
warm and thermostat open. Coolant
should be observed flowing through
radiator. If flow is not observed, determine
area of obstruction and repair as
necessary.
7 - 12 COOLINGDR
COOLING (Continued)

CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
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 or propylene-glycol cool-
ant prevents water present in the cooling system
from freezing within temperatures indicated by mix-
ture ratio of coolant to water.
COOLANT RECOVERY
CONTAINER-5.9L
DESCRIPTION
The coolant reserve/overflow tank is mounted on
top of the fan shroud, and is made of high tempera-
ture plastic (Fig. 1).
OPERATION
The coolant reserve/overflow system works in con-
junction with the radiator pressure cap. It utilizes
thermal expansion and contraction of coolant to keep
coolant free of trapped air. It provides a volume for
expansion and contraction of coolant. It also providesa convenient and safe method for checking coolant
level and adjusting level at atmospheric pressure.
This is done without removing the radiator pressure
cap. The system also provides some reserve coolant
to the radiator to cover minor leaks and evaporation
or boiling losses.
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Cool-
ant will then be drawn from the coolant tank and
returned to a proper level in the radiator.
REMOVAL
(1) Remove recovery hose from radiator.
(2) Remove the coolant container to fan shroud
mounting bolt.
(3) Tilt the container backward towards the engine
to disengage the mounting pin locking features and
lift the container away from the fan shroud (Fig. 1).
INSTALLATION
(1) Align the coolant container mounting pins into
the slots on the fan shroud and push the container
onto the fan shroud.
(2) Secure the container to the fan shroud with the
bolt. Tighten to 8.5N´m (75 in-lbs).
NOTE: Ensure that the locking feature on the
mounting pins has engaged.
(3) Connect the recovery hose to the radiator (Fig.
1).
COOLANT DEGAS
CONTAINER-3.7L/4.7L
DESCRIPTION
The coolant degas container is mounted on top of
the fan shroud and is made of high temperatyre plas-
tic (Fig. 2).
OPERATION
The coolant degas system works in parallel with
the radiator. It is fed through a vent line connected
to the top of the radiator inlet tank and returns to
the engine/coolant pump via the heater return hoses.
This plumbing arrangement, together with the inlet
thermostat, provides for constant flow through the
degas container whenever the engine is running. The
air space in the top of the degas container serves sev-
eral functions. It provides a volume for the expansion
of coolant during engine operation. It provides a
space for quick de-aeration of the coolant. Since the
container is the highest point in the cooling system,
any air trapped in the coolant will quickly be trans-
ported to the degas container and be separated out.
Fig. 1 Coolant Recovery Bottle Ð 5.9L
1 - SCREW
2 - COOLANT RECOVERY CONTAINER
3 - RADIATOR/RADIATOR CAP
4 - FAN SHROUD
7 - 38 ENGINEDR
COOLANT (Continued)

The air space also acts as sort of a spring that pro-
vides constant system pressurization in conjunction
with the radiator cap on top of the container. By
returning coolant to the pump side of the inlet ther-
mostat, the degas container also supplies greater
pressure to the coolant pump, providing for enhanced
coolant flow at high engine speeds.
The degas container also provides a convenient and
safe method for checking the coolant level with out
removing the radiator pressure cap. The degas con-
tainer does not require a separate overflow container
since it was designed with enough volume to provide
a coolant reserve and also protect for any after-boil
conditions.
REMOVAL
(1) Drain enough coolant from the system so that
the degas container is empty. Refer to Draining Cool-
ing System 3.7L/4.7L Engines in this group
(2) Loosen the clamps securing the supply and
return hoses to the container and remove the hoses.
(3) Remove the coolant container to fan shroud
mounting bolts.
(4) Tilt the container back towards the engine to
disengage the mounting pin locking features and lift
the container away from the fan shroud.
INSTALLATION
(1) Align the mounting pins into the slots on the
fan shroud and push the container into the fan
shroud.
(2) Secure the coolant container to the fan shroud
with bolts. Tighten to 8.5 N-m (75 in. lbs).
NOTE: Ensure the locking feature on the mounting
pins has engaged.
(3) Connect the supply and return hoses to the
container and ensure that the hose clamps are posi-
tioned properly.
(4) Refill the cooling system(Refer to 7 - COOLING
- STANDARD PROCEDURE).
RADIATOR FAN
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 negative battery cable from battery.
(2) Remove coolant reserve/overflow container from
fan shroud and lay aside.Do Notdisconnect the
hoses or drain coolant from the container.
(3) The thermal viscous fan drive/fan blade assem-
bly is attached (threaded) to the water pump hub
shaft (Fig. 4). Remove the fan blade/viscous fan drive
assembly from the water pump by turning the
mounting nut counterclockwise as viewed from the
front. Threads on the viscous fan drive areRIGHT-
HAND.A 36 MM Fan Wrench should be used to pre-
vent pulley from rotating (Fig. 3).
(4)Do Notattempt to remove the fan/viscous fan
drive assembly from the vehicle at this time.
(5)Do Notunbolt the fan blade assembly (Fig. 4)
from viscous fan drive at this time.
(6) Remove the fan shroud-to-radiator mounting
bolts.
(7) Pull the lower shroud mounts out of the radia-
tor tank clips.
(8) Remove the fan shroud and fan blade/viscous
fan drive assembly as a complete unit from vehicle.
(9) After removing the fan blade/viscous fan drive
assembly,do notplace the viscous fan drive in a
horizontal position. If stored horizontally, silicone
Fig. 2 Coolant Degas Container
1 - SCREWS
2 - COOLANT DEGAS CONTAINER
3 - FAN SHROUD
4 - RADIATOR
DRENGINE 7 - 39
COOLANT DEGAS CONTAINER-3.7L/4.7L (Continued)

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.
CAUTION: A number or letter is stamped into the
tongue of the constant tension clamps (Fig. 21). If
replacement is necessary, use only an original
equipment clamp with a matching number, letter
and width.
(7) Remove the radiator upper hose clamp and
upper hose at the thermostat housing.
(8) Position the wiring harness (behind thermostat
housing) to gain access to the thermostat housing.
(9) Remove the thermostat housing mounting
bolts, thermostat housing, gasket and thermostat
(Fig. 22). Discard old gasket.
INSTALLATION
(1) Clean the mating areas of the intake manifold
and thermostat housing.
(2) Install the thermostat (spring side down) into
the recessed machined groove on the intake manifold
(Fig. 22).
(3) Install the gasket on the intake manifold and
over the thermostat (Fig. 22).(4) Position the thermostat housing to the intake
manifold.Note:The word FRONT stamped on hous-
ing (Fig. 23). For adequate clearance, thismustbe
placed towards the front of the vehicle. The housing
is slightly angled forward after the installation to the
intake manifold.
(5) Install the housing-to-intake manifold bolts.
Tighten the bolts to 23 N´m (200 in. lbs.).
Fig. 20 Automatic Belt Tensioner ± 5.9L Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
Fig. 21 SPRING CLAMP SIZE LOCATION
1 - SPRING CLAMP SIZE LOCATION
Fig. 22 Thermostat ± 5.9L Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
DRENGINE 7 - 49
ENGINE COOLANT THERMOSTAT- 5.7L/5.9L (Continued)