water JEEP LIBERTY 2002 KJ / 1.G Service Manual

NOTE: The engine cooling system will push any
remaining air into the coolant bottle within about an
hour of normal driving. As a result, a drop in cool-
ant level in the pressure bottle may occur. If the
engine cooling system overheats and pushes cool-
ant into the overflow side of the coolant bottle, this
coolant will be sucked back into the cooling system
ONLY IF THE PRESSURE CAP IS LEFT ON THE
BOTTLE. Removing the pressure cap breaks the
vacuum path between the two bottle sections and
the coolant will not return to cooling system.
(3) With heater control unit in the HEAT position,
operate engine with pressure bottle cap in place.
(4) Add coolant to pressure bottle as necessary.
Only add coolant to the pressure bottle when
the engine is cold. Coolant level in a warm
engine will be higher due to thermal expansion.
NOTE: The coolant bottle has two chambers. Cool-
ant will normally only be in the outboard (larger) of
the two. The inboard chamber is only to recover
coolant in the event of an overheat or after a recent
service fill. The inboard chamber should normally
be empty. If there is coolant in the overflow side of
the coolant bottle (after several warm/cold cycles of
the engine) and coolant level is above cold full
when cold, disconnect the end of the overflow hose
at the fill neck and lower it into a clean container.
Allow coolant to drain into the container until emp-
tied. Reconnect overflow hose to fill neck.
STANDARD PROCEDURE - COOLING SYSTEM -
REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-110 kPa (14-to -16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse flushing of the cooling system is the forc-
ing of water through the cooling system. This is done
using air pressure in the opposite direction of normal
coolant flow. It is usually only necessary with very
dirty systems with evidence of partial plugging.
CHEMICAL CLEANING
If visual inspection indicates the formation of
sludge or scaly deposits, use a radiator cleaner
(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
CAUTION: Be sure instructions on the container are
followed.
REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.
CAUTION: The cooling system normally operates at
97-to-110 kPa (14- to-16 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator
is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
ment. Have radiator cleaned more extensively by a
radiator repair shop.
REVERSE FLUSHING ENGINE
Drain the cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). Remove the thermostat
housing and thermostat. Install the thermostat hous-
ing. Disconnect the radiator upper hose from the
radiator and attach the flushing gun to the hose. Dis-
connect the radiator lower hose from the water
pump. Attach a lead away hose to the water pump
inlet fitting.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
water. When the engine is filled, apply air in short
blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo-
stat housing (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT - REMOVAL).
Install the thermostat and housing with a replace-
ment gasket (Refer to 7 - COOLING/ENGINE/EN-
GINE COOLANT THERMOSTAT -
INSTALLATION). Connect the radiator hoses. Refill
the cooling system with the correct antifreeze/water
mixture (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).
7s - 12 COOLING - 2.4LKJ
COOLING - 2.4L (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Automatic Belt Tensioner to
Mounting
Bracket
2.4L 41 30 -
3.7L 41 30 Ð
Automatic Belt Tensioner
PulleyÐ
Bolt
(2.4L) 61 45 Ð
(3.7L) 61 45 Ð
Block HeaterÐBolt
2.4L 2 Ð 17
3.7L 2 Ð 17
Condenser to Radiator Bolts 8 70
Coolant Overflow Bottle to
Plenum mounting bolts - 2.4L
only8.5 75
Coolant Pressure Bottle to
Plenum mounting bolts -3.7L
only8.5 75
Electric Fan to Fan Shroud
bolts5.5 50
Fan Blade Assy. to Viscous
Drive
Bolts 3.7L 23 Ð 210
Fan Shroud to Radiator
Mounting Bolts8Ð70
Radiator Upper Isolator to
Crossmember - Bolts 9.5 Ð 85
Thermostat HousingÐBolts
2.4L 28 - 250
4.7L 13 Ð 115
Water PumpÐBolts
2.4L 12 Ð 105
4.7L 54 40 Ð
SPECIAL TOOLS
COOLING
Pliers 6094
Adapter Pins 8346
Spanner Wrench 6958 with 8346 adapter pins
Pressure Tester 7700±A
Coolant Refractometer 8286
KJCOOLING - 2.4L7s-13
COOLING - 2.4L (Continued)

INSTALLATION - 2.4L ENGINE
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label. This label is located
in the engine compartment.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.
(2) Install new belt (Fig. 3) or (Fig. 4). Route the
belt around all pulleys except the idler pulley. Rotate
the tensioner arm until it contacts its stop position.
Route the belt around the idler and slowly let the
tensioner rotate into the belt. Make sure the belt is
seated onto all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator. On 2.4L Engines the gap between the
tang and the housing stop ( measurement A ) must
not exceed 24 mm (.94 inches).
Fig. 3 BELT ROUTING 2.4L WITH A/C
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - ACCESSORY DRIVE BELT
Fig. 4 BELT ROUTING 2.4L WITHOUT A/C
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - IDLER PULLEY
4 - POWER STEERING PUMP PULLEY
5 -CRANKSHAFT PULLEY
6 - TENSIONER
7 - NON A/C IDLER PULLEY
8 - ACCESSORY DRIVE BELT
KJACCESSORY DRIVE7s-17
DRIVE BELTS -2.4L (Continued)

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION
DESCRIPTION - HOAT COOLANT.........18
DESCRIPTION - ENGINE COOLANT.......19
OPERATION...........................20
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION.........................20
OPERATION...........................20
ENGINE BLOCK HEATER - 2.4L
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL - 2.4L........................20
INSTALLATION - 2.4L....................20
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
ENGINE COOLANT THERMOSTAT
REMOVAL - 2.4L ENGINE.................22
INSTALLATION - 2.4L ENGINE.............22
RADIATOR
DESCRIPTION.........................22REMOVAL.............................22
CLEANING............................24
INSPECTION..........................24
INSTALLATION.........................24
RADIATOR PRESSURE CAP
DESCRIPTION.........................25
OPERATION...........................25
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP......................25
CLEANING............................25
INSPECTION..........................25
RADIATOR FAN - ELECTRIC
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................26
INSTALLATION.........................27
WATER PUMP - 2.4L
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL - 2.4L ENGINE.................27
INSPECTION..........................28
INSTALLATION - 2.4L ENGINE.............28
COOLANT
DESCRIPTION
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHENENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5 Year/100,000
Mile Formula (MS-9769), or the equivalent ethylene
glycol base coolant with organic corrosion inhibitors
(called HOAT, for Hybrid Organic Additive Technology)
is recommended. This coolant offers the best engine
cooling without corrosion when mixed with 50% Eth-
ylene Glycol and 50% distilled water to obtain a freeze
point of -37ÉC (-35ÉF). If it loses color or becomes con-
taminated, drain, flush, and replace with fresh prop-
erly mixed coolant solution.
7s - 18 ENGINEKJ

CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres-
ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise to as high as 149ÉC
(300ÉF). This temperature is hot enough to melt plas-
tic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - ENGINE COOLANT
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. The
increased 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.
KJENGINE7s-19
COOLANT (Continued)

Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene 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 indicated by mixture ratio of coolant to
water.
COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
This system works along with the radiator pres-
sure cap. This is done by using thermal expansion
and contraction of the coolant to keep the coolant
free of trapped air. It provides:
²A volume for coolant expansion and contraction.
²A convenient and safe method for checking/ad-
justing coolant level at atmospheric pressure. This is
done without removing the radiator pressure cap.
²Some 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.
The coolant reservoir/overflow system has a radia-
tor mounted pressurized cap, an overflow tube, and a
plastic coolant reservoir/overflow tank, mounted to
the right side of the cowl. It is mounted to the cowl
with two nuts on top, and a slide bracket on the bot-
tom.
OPERATION
The pressure chamber keeps the coolant free of
trapped air, provides a volume for expansion and con-
traction, and provides a convenient and safe method
for checking and adjusting coolant level at atmo-
spheric pressure. It also provides some reserve cool-
ant to cover minor leaks, evaporation or boiling
losses. The overflow chamber allows coolant recovery
in case of an overheat.
ENGINE BLOCK HEATER - 2.4L
DESCRIPTION
The block heater is operated by ordinary house
current (110 Volt A.C.) through a power cord and con-
nector located in the engine compartment. The
heater is mounted in a core hole (in place of a core
hole plug) in the engine block, with the heating ele-
ment immersed in coolant.
CAUTION: The power cord must be secured in its
retainer clips, and not positioned so it could con-
tact linkages or exhaust manifolds and become
damaged.
OPERATION
The block heater element is submerged in the cool-
ing system's coolant. When electrical power (110 volt
A.C.) is applied to the element, it creates heat. This
heat is transferred to the engine coolant. This pro-
vides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures.
REMOVAL - 2.4L
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(2) Raise vehicle on hoist.
(3) Detach power cord plug from heater.
(4) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION - 2.4L
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly (Fig. 1) with element
loop positionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
CAUTION: To prevent damage, the power cord must
be secured in it's retaining clips, and not positioned
so it could contact linkages or exhaust manifold.
(4) Connect power cord to heater.
(5) Lower vehicle.
(6) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
7s - 20 ENGINEKJ
COOLANT (Continued)

ENGINE COOLANT
TEMPERATURE SENSOR
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-width²Spark-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
2.4L
The Engine Coolant Temperature (ECT) sensor is
installed into a water jacket at left front of cylinder
head (Fig. 2).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Partially drain cooling system.
(2) Disconnect electrical connector from sensor.
(3) Remove sensor from cylinder head.
3.7L
The Engine Coolant Temperature (ECT) sensor is
installed into a water jacket at front of intake mani-
fold near rear of generator (Fig. 3).
Fig. 1 ENGINE BLOCK HEATER 2.4L
1 - CORE HOLE
2 - BLOCK HEATER
3 - POWER CORD
Fig. 2 ECT AND UPPER TIMING BELT COVER/
BOLTS-2.4L
1 - UPPER TIMING BELT COVER
2 - ELECTRICAL CONNECTOR (ECT)
3 - MOUNTING BOLTS (3)
KJENGINE7s-21
ENGINE BLOCK HEATER - 2.4L (Continued)

WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Partially drain cooling system.
(2) Disconnect electrical connector from sensor.
(3) Remove sensor from intake manifold.
INSTALLATION
(1) Apply thread sealant to sensor threads.
(2) Install sensor to engine.
(3) Tighten sensor to 11 N´m (8 ft. lbs.) torque.
(4) Replace any lost engine coolant.
ENGINE COOLANT
THERMOSTAT
REMOVAL - 2.4L ENGINE
(1) Drain cooling system below the thermostat
level.
(2) Remove radiator upper hose from the coolant
outlet housing.
(3) Remove coolant outlet housing bolts and hous-
ing.
(4) Remove thermostat. Discard gasket and clean
both gasket sealing surfaces.
INSTALLATION - 2.4L ENGINE
(1) Place a new gasket (dipped in clean water) on
the coolant outlet connector surface. Position thermo-
stat with air bleed at the 12 o'clock position in ther-
mostat housing.
(2) Position the coolant outlet connector and gas-
ket over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Position outlet connector to thermostat housing
and install bolts. Tighten bolts to 28 N´m (250 in.
lbs.).
(4) Install the radiator upper hose to coolant outlet
housing.
(5) Refill the cooling system.
RADIATOR
DESCRIPTION
All vehicles are equipped with a cross flow type
radiator with plastic side tanks (Fig. 4).
Plastic tanks, while stronger than brass, are sub-
ject to damage by impact, such as from tools or
wrenches. Handle radiator with care.
REMOVAL
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. REFER TO COOLING SYSTEM DRAIN-
ING.
Fig. 3 MAP SENSOR / ECT SENSOR - 3.7L
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
Fig. 4 Cross Flow Radiator - Typical
1 - RADIATOR
7s - 22 ENGINEKJ
ENGINE COOLANT TEMPERATURE SENSOR (Continued)

(8) Disconnect the power steering cooler line from
cooler.
(9) Disconnect the radiator upper and lower hoses.
(10) Disconnect the overflow hose from radiator.
(11) The lower part of radiator is equipped with
two alignment dowel pins (Fig. 8). They are located
on the bottom of radiator tank and fit into rubber
grommets. These rubber grommets are pressed into
the radiator lower crossmember.
WARNING: THE AIR CONDITIONING SYSTEM (IF
EQUIPPED) IS UNDER A CONSTANT PRESSURE
EVEN WITH THE ENGINE OFF. REFER TO REFRIG-
ERANT WARNINGS IN, HEATING AND AIR CONDI-
TIONING BEFORE HANDLING ANY AIR
CONDITIONING COMPONENT.
NOTE: The radiator and radiator cooling fan can be
removed as an assembly. It is not necessary to
remove the cooling fan before removing or install-
ing the radiator.
(12) Gently lift up and remove radiator from vehi-
cle. Be careful not to scrape the radiator fins against
any other component. Also be careful not to disturb
the air conditioning condenser (if equipped).CLEANING
Clean radiator fins With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con-
denser of debris.
INSPECTION
The radiator cooling fins should be checked for
damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C condenser rubber air seals are properly
fastened to their original positions. These are used
at the top, bottom and sides of the radiator and A/C
condenser. To prevent overheating, these seals
must be installed to their original positions.
(1) Gently lower the radiator and fan shroud into
the vehicle. Guide the two radiator alignment dowels
into the rubber grommets located in lower radiator
crossmember.
(2) Connect the radiator upper and lower hoses
and hose clamps to radiator.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(3) Install coolant reserve/overflow tank hose at
radiator.
(4) Connect both transmission cooler lines at the
radiator.
(5) Install both radiator mounting bolts.
(6) Reconnect the electric cooling fan.
(7) Install the grill (Refer to 23 - BODY/EXTERI-
OR/GRILLE - INSTALLATION).
(8) Reinstall the cooling fan to the engine.
(9) Rotate the fan blades (by hand) and check for
interference at fan shroud.
(10) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect battery cable at battery.
(12) Start and warm engine. Check for leaks.
Fig. 8 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
7s - 24 ENGINEKJ
RADIATOR (Continued)

RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system cap is located on the coolant
pressure bottle. The cap construction includes; stain-
less steel swivel top, rubber seals and retainer, main
spring, and a spring loaded valve (Fig. 9).
OPERATION
The pressure cap allows the cooling system to oper-
ate at higher than atmospheric pressure which raises
the coolant boiling point, thus allowing increased
radiator cooling capacity. The pressure cap releases
pressure at some point within a range of 110 kPa  
14 kPa (16 psi   2 psi).
A spring-loaded vent valve in the center of the cap
allows the system to pressurize and depressurize
without creating a vacuum. If the valve is stuck
open, coolant will escape to the overflow hose. There
is also a gasket in the cap to seal to the top of the
filler neck.
CAUTION: Use only the pressure cap specified for
this vehicle. Use of other pressure caps can lead to
coolant loss and overheating.
DIAGNOSIS AND TESTING - RADIATOR
PRESSURE CAP
Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install the cap on pressure tester (tool 7700 or
an equivalent) (Fig. 10).Operate the tester pump and observe the gauge
pointer at its highest point. The cap release pressure
should be 124 to 145 kPa (18 to 21 psi). The cap is
satisfactory when the pressure holds steady. It is also
good if it holds pressure within the 124 to 145 kPa
(18 to 21 psi) range for 30 seconds or more. If the
pointer drops quickly, replace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Clean the radiator pressure cap using a mild soap
and water only.
INSPECTION
Visually inspect the pressure valve gasket on the
cap. Replace cap if the gasket is swollen, torn or
worn. Inspect the area around radiator filler neck for
white deposits that indicate a leaking cap.
Fig. 9 PRESSURE CAP
1 - MAIN SPRING
2 - GASKET RETAINER
3 - STAINLESS STEEL SWIVEL TOP
4 - RUBBER SEALS
5 - SPRING LOADED VALVE
6 - COOLANT PRESSURE BOTTLE
7 - FILLER NECK
8 - OVERFLOW NIPPLEFig. 10 Pressure Testing Radiator Pressure Cap -
Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
KJENGINE7s-25