clutch DODGE RAM 2003 Service Service Manual

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
10. Radiator or A/C condenser
fins are dirty or clogged.10. Remove insects and debris. (Refer to
7 - COOLING - STANDARD
PROCEDURE).
11. Radiator core is corroded or
plugged.11. Have radiator re-cored or replaced.
12. Fuel or ignition system
problems.12. Refer to 14 - Fuel System or 8 -
Electrical for diagnosis and testing
procedures.
13. Dragging brakes. 13. Check and correct as necessary.
(Refer to 5 - BRAKES - DIAGNOSIS AND
TESTING) for correct procedures.
14. Bug screen or cardboard is
being , reducing airflow.14. Remove bug screen or cardboard.
15. Thermostat partially or
completely shut.15. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT
THERMOSTAT - REMOVAL) .
16. Viscous fan drive not
operating properly.16. Check fan drive operation and replace
as necessary. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL).
17. Cylinder head gasket
leaking.17. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
18. Heater core leaking. 18. Check heater core for leaks. (Refer to
24 - HEATING & AIR CONDITIONING/
PLUMBING - DIAGNOSIS AND
TESTING). Repair as necessary.
DRCOOLING 7 - 13
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-
IGNITION (NOT CAUSED BY
IGNITION SYSTEM). GAUGE
MAY OR MAY NOT BE
READING HIGH1. Engine overheating. 1. Check reason for overheating and
repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.2. Check coolant concentration. (Refer to
LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION).
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING1. Vacuum created in cooling
system on engine cool-down is
not being relieved through
coolant reserve/overflow system.1. (a) Radiator cap relief valve stuck.
(Refer to 7 - COOLING/ENGINE/
RADIATOR PRESSURE CAP -
DIAGNOSIS AND TESTING). Replace if
necessary
(b) Hose between coolant
reserve/overflow tank and
radiator is kinked. Repair as
necessary.
(c) Vent at coolant reserve/
overflow tank is plugged. Clean
vent and repair as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for blockage
and repair as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly. (Refer to 7
- COOLING/ENGINE/RADIATOR FAN -
REMOVAL)
2. Fan blades striking a
surrounding object.2. Locate point of fan blade contact and
repair as necessary.
3. Air obstructions at radiator or
air conditioning condenser.3. Remove obstructions and/or clean
debris or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has
defective bearing.4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL).
5. A certain amount of fan noise
may be evident on models
equipped with a thermal viscous
fan drive. Some of this noise is
normal.5. (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH -
DESCRIPTION) for an explanation of
normal fan noise.
DRCOOLING 7 - 15
COOLING (Continued)

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT.......36
DESCRIPTION - HOAT COOLANT.........37
OPERATION...........................38
COOLANT RECOVERY CONTAINER-5.9L
DESCRIPTION.........................38
OPERATION...........................38
REMOVAL.............................38
INSTALLATION.........................38
COOLANT DEGAS CONTAINER-3.7L/4.7L
DESCRIPTION.........................38
OPERATION...........................38
REMOVAL.............................39
INSTALLATION.........................39
RADIATOR FAN
REMOVAL.............................39
CLEANING............................40
INSPECTION..........................40
INSTALLATION.........................40
RADIATOR FAN - 5.9L DIESEL
REMOVAL.............................41
CLEANING............................41
INSPECTION..........................41
INSTALLATION.........................41
ENGINE BLOCK HEATER
DESCRIPTION.........................42
OPERATION...........................42
DIAGNOSIS AND TESTING Ð ENGINE BLOCK
HEATER ............................42
REMOVAL.............................43
INSTALLATION.........................43
ENGINE BLOCK HEATER - 5.9L DIESEL
DESCRIPTION.........................43
OPERATION...........................43
REMOVAL.............................43
INSTALLATION.........................44
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION.........................44
OPERATION...........................44
REMOVAL.............................44
INSTALLATION.........................47
ENGINE COOLANT THERMOSTAT- 5.7L/5.9L
DESCRIPTION.........................47
OPERATION...........................48
DIAGNOSIS AND TESTINGÐTHERMOSTAT . . . 48
REMOVAL.............................48
INSTALLATION.........................49
ENGINE COOLANT THERMOSTAT - 3.7L/4.7L
DESCRIPTION.........................50OPERATION...........................51
DIAGNOSIS AND TESTINGÐTHERMOSTAT . . . 51
REMOVAL.............................51
INSTALLATION.........................51
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL
DESCRIPTION.........................52
OPERATION...........................52
DIAGNOSIS AND TESTINGÐTHERMOSTAT . . . 52
REMOVAL.............................53
INSTALLATION.........................53
FAN DRIVE VISCOUS CLUTCH
DESCRIPTION.........................54
OPERATION...........................54
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE..............................54
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL
DESCRIPTION.........................55
OPERATION...........................55
DIAGNOSIS AND TESTING - ELECTRONICLY
CONTOLLED VISCOUS FAN DRIVE.......56
RADIATOR
DESCRIPTION.........................56
OPERATION...........................56
DIAGNOSIS AND TESTINGÐRADIATOR
COOLANT FLOW......................57
REMOVAL.............................57
CLEANING............................58
INSPECTION..........................58
INSTALLATION.........................58
RADIATOR - 5.9L DIESEL
DESCRIPTION.........................59
OPERATION...........................59
DIAGNOSIS AND TESTINGÐRADIATOR
COOLANT FLOW......................59
REMOVAL.............................59
CLEANING............................60
INSPECTION..........................60
INSTALLATION.........................60
RADIATOR PRESSURE CAP
DESCRIPTION.........................60
OPERATION...........................61
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐRADIATOR
CAP-TO-FILLER NECK SEAL.............61
DIAGNOSIS AND TESTING - RADIATOR
CAP................................61
CLEANING............................62
INSPECTION..........................62
DRENGINE 7 - 35

(7) Start the engine and check for coolant leaks.
Run engine to check for proper thermostat operation.
FAN DRIVE VISCOUS CLUTCH
DESCRIPTION
The thermal viscous fan drive (Fig. 29) is a sili-
cone-fluid- filled coupling used to connect the fan
blades to the water pump shaft. The coupling allows
the fan to be driven in a normal manner. This is
done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
OPERATION
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit (a typical
viscous unit is shown in (Fig. 30). This spring coil
reacts to the temperature of the radiator discharge
air. It engages the viscous fan drive for higher fan
speed if the air temperature from the radiator rises
above a certain point. Until additional engine cooling
is necessary, the fan will remain at a reduced rpm
regardless of engine speed.
Only when sufficient heat is present, will the vis-
cous fan drive engage. This is when the air flowing
through the radiator core causes a reaction to the
bimetallic coil. It then increases fan speed to provide
the necessary additional engine cooling.Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
²The underhood temperature is above the engage-
ment point for the viscous drive coupling. This may
Fig. 28 Thermostat Removal/Installation
1 - THERMOSTAT HOUSING
2 - CYLINDER HEAD
3 - THERMOSTAT
Fig. 29 Viscous Fan
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
Fig. 30 Viscous Fan DriveÐTypical
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
7 - 54 ENGINEDR
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)

occur when ambient (outside air temperature) is very
high.
²Engine loads and temperatures are high such as
when towing a trailer.
²Cool silicone fluid within the fan drive unit is
being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
VISCOUS DRIVE
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against exces-
sively high coolant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Drill a 3.18-mm (1/8-in) diameter hole in the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
(or equivalent). It should have a range of -18É-to-
105ÉC (0É-to-220É F). Insert thermometer through the
hole in the shroud. Be sure that there is adequate
clearance from the fan blades.
(3) Connect a tachometer and an engine ignition
timing light. The timing light is to be used as a
strobe light. This step cannot be used on the diesel
engine.
(4) Block the air flow through the radiator. Secure
a sheet of plastic in front of the radiator. Use tape at
the top to secure the plastic and be sure that the air
flow is blocked.
(5) Be sure that the air conditioner (if equipped) is
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engine and operate at 2400 rpm.
Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 88É C (190É F).
Fan driveengagementshould start to occur at/be-
tween:
²3.7L Automatic Ð 93É C - 99ÉC (200É F - 210É F)²3.7L Manual/4.7L Automatic/5.9L Ð 85É to 91É C
(185É to 195É F)
²4.7L Manual Ð 74É to 79É C (165É to 175É F)
²Engagement is distinguishable by a definite
increasein fan flow noise (roaring). The timing light
also will indicate an increase in the speed of the fan.
(7) When viscous drive engagement is verified,
remove the plastic sheet. Fan drivedisengagement
should start to occur at or between:
²3.7L Automatic Ð 76ÉC to 81ÉC (168É F to 178É
F)
²3.7L Manual/4.7L Auto/ 5.9L Ð 67ÉC to 73ÉC
(153É F to 163É F)
²4.7L Manual Ð 56ÉC to 62ÉC (133É F to 143É F)
²8.0L engine Ð 88É to 96É C (190É to 205É F) A
definitedecreaseof fan flow noise (roaring) should
be noticed. If not, replace the defective viscous fan
drive unit.
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.
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.
FAN DRIVE VISCOUS CLUTCH
- 5.9L DIESEL
DESCRIPTION
The electronically controlled thermal viscous fan
drive (Fig. 31) is attached to the fan drive pulley
mounted to the engine. The coupling allows the fan
to be driven in a normal manner. The fan speed is
controlled by the electronic control module.
OPERATION
The Engine Control Module (ECM) controls the
level of engagment of the electronically controlled
viscous fan clutch by monitoring coolant tempera-
ture, intake manifold temperature, and air condition-
ing status. Based on cooling requirements, the ECM
sends a signal to the viscous fan clutch to increase or
decrease the fan speed.
DRENGINE 7 - 55
FAN DRIVE VISCOUS CLUTCH (Continued)

Fan speed is monitored by the ECM. A lack of fan
speed will set a DTC. Circuit concerns will also set
fan clutch DTC's.
Fan speed and duty cycle percent can be monitored
with the DRB III..
DIAGNOSIS AND TESTING - ELECTRONICLY
CONTOLLED VISCOUS FAN DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
²Fan duty cycle high. This may occur when ambi-
ent (outside air temperature) is very high.
²Engine loads and temperatures are high such as
when towing a trailer.
²Cool silicone fluid within the fan drive unit is
being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
ELECTRONICALLY CONTROLLED VISCOUS DRIVE
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against exces-
sively high coolant temperature.
The Electronic Viscous Fan drive can be tested
using the DRB III scan tool.
(1) Set the parking brake and verify the transmis-
sion is in park or neutral.
(2) Stat and allow engine to reach normal operat-
ing termeratures.
(3) With engine idling, connect the DRB III and
select appropraite model year and engine option.
(4) Lacate and select actuator tests, then select
PWM Viscous Fan.
(5) Monitor fan speed and duty cycle; verify that
the fan speed increments are proportional to the duty
cycle precentage during the actuation event.
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.
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.
RADIATOR
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and verti-
cal plastic side tanks (Fig. 32).
This radiator does not contain an internal trans-
mission oil cooler
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radiator core to cool the engine.
Fig. 31 Fan Blade/Viscous Fan Drive
1 - ELECTRICAL CONNECTOR
2 - VISCOUS FAN DRIVE
3 - FAN BLADE
4 - BOLT
5 - FAN DRIVE
7 - 56 ENGINEDR
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued)

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 the negative cable.
(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 the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) (Fig. 41).
(5) Remove the lower radiator hose and heater
hose from the water pump.
(6) Loosen the heater hose coolant return tube
mounting bolt (Fig. 42) and remove the tube from the
water pump. Discard the old tube O-ring.
(7) Remove the water pump mounting bolts (Fig.
43).(8) Loosen the clamp at the water pump end of
bypass hose (Fig. 42). Slip the bypass hose from the
Fig. 40 Water Pump Location Ð Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
Fig. 41 Belt Tensioner 5.9L V-8 Engine
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
Fig. 42 Coolant Return Tube 5.9L
1 - COOLANT RETURN TUBE
2 - WATER PUMP
3 - TUBE MOUNTING BOLT
4 - O-RING
DRENGINE 7 - 63
WATER PUMP - 5.9L (Continued)

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.
OPERATIONÐWATER PUMP BYPASS
When the thermostat is in the closed position the
bypass gallery is not obstructed allowing 100% flow.
When the thermostat is in the open position the stub
shaft enters the bypass gallery obstructing bypass
coolant flow by 50%. This design allows the coolant
to reach operating temperature quickly when cold,
while adding extra cooling during normal tempera-
ture operation.
REMOVAL
The water pump on 3.7L/4.7L engines is bolted
directly to the engine timing chain case cover.
(1) Disconnect the negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan/viscous fan drive assembly from
water pump (Fig. 46) (Refer to 7 - COOLING/EN-
GINE/FAN DRIVE VISCOUS CLUTCH - REMOV-
AL). Do not attempt to remove fan/viscous fan drive
assembly 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. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT 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 matching number or letter and width.
(4) If the water pump is being replaced, do not
unbolt the fan blade assembly from the thermal vis-
cous fan drive.
(5) Remove the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove accessory drive belt (Fig. 47) (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove the lower radiator hose clamp and
remove the lower hose at the water pump.
(8) Remove the water pump mounting bolts.
Fig. 44 Water Pump and Timing Chain Cover
1 - INTEGRAL WATER PUMP PULLEY
2 - TIMING CHAIN COVER
3 - THERMOSTAT HOUSING
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
Fig. 45 Water/Coolant Bypass Flow and Thermostat
1 - FROM HEATER AND DEGAS CONTAINER
2 - FROM RADIATOR
3 - TO WATER PUMP
4 - ENGINE BYPASS
5 - THERMOSTAT
DRENGINE 7 - 65
WATER PUMP - 3.7L/4.7L (Continued)

CAUTION: A number or letter is stamped into the
tongue of the constant tension clamps. If replace-
ment is necessary, use only an original equipment
clamp with a matching number or letter and width.
(2) Loosen both of the bypass hose clamps and
position them to the center of the hose.
(3) Removethe hose from the vehicle.
INSTALLATION
INSTALLATION - WATER PUMP BYPASS HOSE
WITH AIR CONDITIONING
(1) Position the bypass hose clamps to the center
of the bypass hose.
(2) Install the bypass hose to the engine.
(3) Secure both of the hose clamps.
(4) Install the generator-A/C mounting bracket
assembly to the engine. Tighten bolt number 1 (Fig.
53) to 41 N´m (30 ft. lbs.). Tighten bolt number 2
(Fig. 53) to 28 N´m (20 ft. lbs.). Tighten bracket
mounting bolts (Fig. 53) (Fig. 53) to 40 N´m (30 ft.
lbs.).
(5) Install a new O-ring to the heater hose coolant
return tube. Coat the new O-ring with antifreeze
before installation.
(6) Install the coolant return tube and its mount-
ing bolt to the engine.
(7) Connect the throttle body control cables.
(8) Install the oil dipstick mounting bolt.
(9) Install the idler pulley. Tighten the bolt to 41
N´m (30 ft. lbs.) (Fig. 57).
(10) Install the drive belt (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).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 (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION). The correct belt with the correct length must
be used.
(11) Install the air cleaner assembly.
(12) Install the upper radiator hose to the radiator.
(13) Connect the throttle cable to the clip at the
radiator fan shroud.
(14) Connect the wiring harness to the A/C com-
pressor.
(15) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(16) Start and warm the engine. Check for leaks.
INSTALLATION - WATER PUMP BYPASS HOSE
WITHOUT AIR CONDITIONING
(1) Position the bypass hose clamps to the center
of the bypass hose.
(2) Install the bypass hose tothe engine.
(3) Secure both of the hose clamps.
(4) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(5) Start and warm the engine. Check for leaks.
WATER PUMP - 5.7L
REMOVAL
(1) Disconnect negative battery cable.
(2) Drain coolant.
(3) Remove serpentine belt.
(4) Remove fan clutch assembly.
(5) Remove coolant fill bottle.
Fig. 56 Water Pump Bypass Hose - Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
Fig. 57 Tensioner Mounting
1 - DOWEL PIN HOLE
2 - TENSIONER MOUNTING BRACKET
7 - 70 ENGINEDR
WATER PUMP INLET TUBE - 5.9L (Continued)