Exj 7

XJ COOLING SYSTEM 7-1

COOLING SYSTEM
CONTENTS

page page

GENERAL INFORMATION RADIATOR COOLANT FLOW CHECK . . . . . . . 19
ACCESSORY DRIVE BELT TENSION . . . . . . . . . 3 TESTING COOLING SYSTEM FOR LEAKS . . . 19
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . 20
COOLING SYSTEM COMPONENTS . . . . . . . . . . 2 SERVICE PROCEDURES
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ADDING ADDITIONAL COOLANT—ROUTINE . . 22
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 1 COOLANT LEVEL CHECK—ROUTINE . . . . . . . 22
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 3 COOLANT LEVEL CHECK—SERVICE . . . . . . . 22
RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COOLANT SERVICE . . . . . . . . . . . . . . . . . . . . 22
SYSTEM COOLANT ROUTING . . . . . . . . . . . . . 2 DRAINING AND FILLING COOLING SYSTEM . . 23
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 2 REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELT TENSION . . . . . . . . . 4 AUXILIARY ELECTRIC COOLING FAN . . . . . . . 34
AUTOMATIC TRANSMISSION OIL COOLER . . . 3 COOLANT RESERVE TANK . . . . . . . . . . . . . . . 25
AUXILIARY ELECTRIC COOLING FAN . . . . . . . . 8 COOLING SYSTEM FANS . . . . . . . . . . . . . . . . 37
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . 5 ENGINE ACCESSORY DRIVE BELTS . . . . . . . . 34
COOLANT RESERVE/OVERFLOW SYSTEM . . . 3 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . 34
COOLANT SELECTION-ADDITIVES . . . . . . . . . . 5 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . 4 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 29
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . 6 TRANSMISSION OIL COOLERS . . . . . . . . . . . . 24
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 4 VISCOUS FAN DRIVE REMOVAL/
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 38
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 25
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 7 CLEANING AND INSPECTION
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 6 COOLING SYSTEM CLEANING . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING COOLING SYSTEM HOSES . . . . . . . . . . . . . . . 38
AUXILIARY ELECTRIC COOLING FAN . . . . . . . 21 FAN BLADE INSPECTION . . . . . . . . . . . . . . . . 38
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . 12 RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . 38
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 RADIATOR PRESSURE CAP . . . . . . . . . . . . . . 38
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 9 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . 38
LOW COOLANT LEVEL-AERATION . . . . . . . . . 22 COOLING SYSTEM CAPACITIES . . . . . . . . . . . 38
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 8 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 39
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . 10 SPECIAL TOOLS
PRESSURE TESTING RADIATOR CAPS . . . . . 22 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
RADIATOR CAP-TO-FILLER NECK SEAL—
PRESSURE RELIEF CHECK . . . . . . . . . . . . . 21

GENERAL INFORMATION COOLING SYSTEM
The cooling system regulates engine operating tem-
ENGINE ACCESSORY DRIVE BELTS perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible, maintains
CAUTION: When installing a serpentine accessory normal operating temperature and prevents over-
drive belt, the belt MUST be routed correctly. If not, heating.
the engine may overheat due to water pump rotat- The cooling system also provides a means of heat-
ing in wrong direction. Refer to the appropriate ing the passenger compartment and cooling the auto-
engine Belt Schematic in this group for the correct matic transmission fluid (if equipped). The cooling
belt routing. Or, refer to the Belt Routing Label system is pressurized and uses a centrifugal water
located in the engine compartment. pump to circulate coolant throughout the system.

HEATER CORE RADIATOR UPPER HOSE
TO WATER PUMP
RADIATOR WATER PUMP TO COOLANT
PULLEY RECOVERY
BOTTLE RADIATOR LOWER
HOSE

7-2 COOLING SYSTEM XJ
GENERAL INFORMATION (Continued)
An optional factory installed heavy duty cooling WATER PUMPS
package is available on most models. The package A quick test to determine if the pump is working is
consists of a radiator that has an increased number to check if the heater warms properly. A defective
of cooling fins. Vehicles equipped with a 4.0L 6- cyl- water pump will not be able to circulate heated cool-
inder engine and heavy duty cooling and/or air con- ant through the long heater hose to the heater core.
ditioning also have an auxiliary electric cooling fan.
COOLANT
COOLING SYSTEM COMPONENTS The cooling system is designed around the coolant.
The cooling system consists of: Coolant flows through the engine water jackets
• A radiator absorbing heat produced during engine operation.
• Cooling fan (mechanical and/or electrical) The coolant carries heat to the radiator and heater
• Thermal viscous fan drive core. Here it is transferred to the ambient air pass-
• Fan shroud ing through the radiator and heater core fins. The
• Radiator pressure cap coolant also removes heat from the automatic trans-
• Thermostat mission fluid in vehicles equipped with an automatic
• Coolant reserve/overflow system transmission.
• Transmission oil cooler (if equipped with an
automatic transmission) RADIATORS
• Coolant 2.5L 4–cylinder engine radiators are the down flow
• Water pump type, 4.0L 6-cylinder engine radiators are the cross
• Hoses and hose clamps flow type. Plastic tanks are used on all radiators.

SYSTEM COOLANT ROUTING CAUTION: Plastic tanks, while stronger than brass,
For cooling system flow routings, refer to (Fig. 1) are subject to damage by impact, such as
(Fig. 2). wrenches.

Fig. 1 Coolant Flow—2.5L 4-Cylinder Engine—Typical

TO COOLANT RADIATORWATER PUMP
HEATER CORE TANK HOUSING
OVERFLOW THERMOSTAT
RESERVE/

GENERAL INFORMATION (Continued)
ENGINE BLOCK HEATER
An optional engine block heater is available for all
models. The heater is equipped with a power cord.
The cord is attached to an engine compartment com-
ponent with tie-straps. The heater warms the engine
providing easier engine starting and faster warm-up
in low temperatures. 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. Connect the power cord to a grounded 110-
120 volt AC electrical outlet with a grounded, three-
wire extension cord.

DESCRIPTION AND OPERATION
AUTOMATIC TRANSMISSION OIL COOLER
WATER-TO-OIL COOLER
All models equipped with an automatic transmis-
sion are equipped with a transmission oil cooler
mounted internally within the radiator tank. This
internal cooler is supplied as standard equipment on
all models equipped with an automatic transmission.
Transmission oil is cooled when it passes through
this separate cooler. In case of a leak in the internal
radiator mounted transmission oil cooler, engine cool-
ant may become mixed with transmission fluid or
transmission fluid may enter engine cooling system.
Fig. 2 Coolant Flow—4.0L 6-Cylinder Engine— Both cooling system and transmission should be
Typical drained and inspected if the internal radiator
If the plastic tank has been damaged, the plastic mounted transmission cooler is leaking.
tank and/or o-rings are available for service repair.
Tank replacement should be done by a qualified per- AIR-TO-OIL COOLER
son with proper equipment. An auxiliary air-to-oil transmission oil cooler is
available with most engine packages.
ACCESSORY DRIVE BELT TENSION The auxiliary air-to-oil transmission oil cooler is
Correct accessory drive belt tension is required to located in front of the radiator or A/C condenser (if
ensure optimum performance of belt driven engine equipped) and behind the grill. It is mounted to the
accessories. If specified tension is not maintained, front frame crossmember.
belt slippage may cause: engine overheating, lack of The auxiliary oil coolers on all models operate in
power steering assist, loss of air conditioning capac- conjunction with the internal radiator mounted main
ity, reduced generator output rate, greatly reduced oil cooler. The transmission oil is routed through the
belt life and objectionable under hood noise. main cooler first, then the auxiliary cooler, before
returning to the transmission.
DOMESTIC LEFT HAND DRIVE VEHICLES
Belt tension is adjusted at the power steering COOLANT RESERVE/OVERFLOW SYSTEM
pump bracket and idler pulley assembly. The system works along with the radiator pressure
cap. This is done by using thermal expansion and
DOMESTIC RIGHT HAND DRIVE VEHICLES contraction of the coolant to keep the coolant free of
If equipped with a 4.0L 6-cylinder engine; the ser- trapped air. It provides:
pentine belt is adjusted at the generator mounting • A volume for coolant expansion and contraction.
bracket. When equipped with a 2.5L 4-cylinder • A convenient and safe method for checking/ad-
engine, the serpentine belt is adjusted at the power justing coolant level at atmospheric pressure. This is
steering pump bracket and idler pulley assembly. done without removing the radiator pressure cap.
• Some reserve coolant to the radiator to cover
minor leaks and evaporation or boiling losses.

MOUNTING
CLAMP
BOLTS TUBE TO RADIATOR COOLANT TANK
OVERFLOW
RESERVE/
LOWER
BRACKET

DESCRIPTION AND OPERATION (Continued)
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 reserve/overflow system consists of a
radiator mounted pressurized cap, a plastic reserve/
overflow tank (Fig. 3) (Fig. 4), a tube (hose) connect-
ing the radiator and tank, and an overflow tube on
the side of the tank.

Fig. 4 Reserve/Overflow Tank—With Right Hand
Drive
tested (between two pulleys) to check tension. Do not
allow the gauge (or gauge adapter) to contact any-
thing but the belt.

ENGINE BLOCK HEATER
An optional engine block heater is available for all
models. The heater is equipped with a power cord.
The cord is attached to an engine compartment com-
Fig. 3 Reserve/Overflow Tank—Except Right Hand ponent with tie-straps. The heater warms the engine
Drive providing easier engine starting and faster warm-up
in low temperatures. The heater is mounted in a core
COOLING SYSTEM FANS hole of the engine cylinder block (in place of a freeze
Also refer to either the Viscous Fan Drive and/or
plug) with the heating element immersed in engine
the Auxiliary Electric Cooling Fan.
coolant. Connect the power cord to a grounded 110-
All models are equipped with a mechanical temper-
120 volt AC electrical outlet with a grounded, three-
ature controlled fan. This thermal viscous fan drive
wire extension cord.
is a torque-and-temperature-sensitive clutch unit. It
automatically increases or decreases fan speed to WARNING: DO NOT OPERATE ENGINE UNLESS
provide proper engine cooling. Vehicles with a 4.0L BLOCK HEATER CORD HAS BEEN DISCONNECTED
6-cylinder engine may also have an auxiliary electri- FROM POWER SOURCE AND SECURED IN PLACE.
cal cooling fan; when equipped air conditioning
and/or heavy duty cooling. BLOCK HEATER SPECIFICATIONS
• 2.5L 4-Cylinder Engine: 115 Volts 400 Watts
ACCESSORY DRIVE BELT TENSION • 4.0L 6-Cylinder Engine: 120 Volts 600 Watts
Both the 2.5l and 4.0l engines use one accessory
drive belt. Correct drive belt tension is required to THERMOSTAT
ensure optimum performance of the belt driven A pellet-type thermostat controls the operating
engine accessories. There are different types of temperature of the engine by controlling the amount
adjustment gauges for checking either a serpentine of coolant flow to the radiator. On all engines the
or a conventional “V-type” belt. Refer to the instruc- thermostat is closed below 195°F (90°C). Above this
tions supplied with the gauge. Make sure to use a temperature, coolant is allowed to flow to the radia-
gauge designed specifically for serpentine style belts. tor. This provides quick engine warm-up and overall
Place gauge in the middle of the section of belt being temperature control.

An arrow plus the word UP is stamped on the and water is -32 deg. C (-26 deg. F). 5 deg. C higher
front flange next to the air bleed. The words TO than ethylene-glycol’s freeze point. The boiling point
RAD are stamped on one arm of the thermostat. (protection against summer boil-over) of propylene-
They indicate the proper installed position. glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi),
The same thermostat is used for winter and sum- compared to 128 deg. C (263 deg. F) for ethylene-gly-
mer seasons. An engine should not be operated with- col. Use of propylene-glycol can result in boil-over or
out a thermostat, except for servicing or testing. freeze-up in Chrysler vehicles, which are designed for
Operating without a thermostat causes other prob- ethylene-glycol. Propylene glycol also has poorer heat
lems. These are: longer engine warm-up time, unre- transfer characteristics than ethylene glycol. This
liable warm-up performance, increased exhaust can increase cylinder head temperatures under cer-
emissions and crankcase condensation. This conden- tain conditions.
sation can result in sludge formation.
Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be
CAUTION: Do not operate an engine without a Used in Chrysler Vehicles
thermostat, except for servicing or testing. Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
COOLANT PERFORMANCE components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
ETHYLENE-GLYCOL MIXTURES conventional methods of determining freeze point will
The required ethylene-glycol (antifreeze) and water not be accurate. Both the refractive index and spe-
mixture depends upon the climate and vehicle oper- cific gravity differ between ethylene glycol and propy-
ating conditions. The recommended mixture of 50/50 lene glycol.
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti- CAUTION: Richer antifreeze mixtures cannot be
freeze concentration must always be a minimum of measured with normal field equipment and can
44 percent, year-round in all climates. If percentage cause problems associated with 100 percent ethyl-
is lower than 44 percent, engine parts may be ene-glycol.
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided COOLANT SELECTION-ADDITIVES
with a 68 percent antifreeze concentration, which Coolant should be maintained at the specified level
prevents freezing down to -67.7 deg. C (-90 deg. F). A with a mixture of ethylene glycol-based antifreeze
higher percentage will freeze at a warmer tempera- and low mineral content water. Only use an anti-
ture. Also, a higher percentage of antifreeze can freeze containing ALUGARD 340-2 ௢.
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water. CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
100 Percent Ethylene-Glycol—Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for- RADIATOR PRESSURE CAP
mation of additive deposits in the system, as the cor- All radiators are equipped with a pressure cap.
rosion inhibitive additives in ethylene-glycol require This cap releases pressure at some point within a
the presence of water to dissolve. The deposits act as range of 83-110 kPa (12-16 psi). The pressure relief
insulation, causing temperatures to rise to as high as point (in pounds) is engraved on top of the cap (Fig.
149 deg. C (300) deg. F). This temperature is hot 5).
enough to melt plastic and soften solder. The The cooling system will operate at pressures
increased temperature can result in engine detona- slightly above atmospheric pressure. This results in a
tion. In addition, 100 percent ethylene-glycol freezes higher coolant boiling point allowing increased radi-
at 22 deg. C (-8 deg. F ). ator cooling capacity. The cap contains a spring-
loaded pressure relief valve that opens when system
Propylene-glycol Formulations—Should Not Be Used in pressure reaches release range of 83-110 kPa (12-16
Chrysler Vehicles psi).
Propylene-glycol formulations do not meet A vent valve in the center of cap allows a small
Chrysler coolant specifications. It’s overall effec- coolant flow through cap when coolant is below boil-
tive temperature range is smaller than that of ethyl- ing temperature. The valve is completely closed when
ene-glycol. The freeze point of 50/50 propylene-glycol boiling point is reached. As the coolant cools, it con-

VACUUM VENT VALVE (SHOWN IN SEAL-
CROSS-SECTIONAL VIEW
ING POSITION)
TOP VIEWPRESSURE RATING SEAL
PRESSURE VALVE
FILLER NECK ROTATION DIRECTIONVIEW R STAMPED INTO IMPELLER
FRONT
VIEWED
AS ROTATION DIRECTIONVIEW
BACK
VIEWED
AS

cous fan drive assembly. REVERSE is stamped or
imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into
the back of the water pump impeller (Fig. 6).

Fig. 6 Reverse Rotating Water Pump—Typical
Engines from previous model years, depending
Fig. 5 Radiator Pressure Cap and Filler Neck— upon application, may have been equipped with a for-
Typical ward (clockwise) rotating water pump. Installation of
tracts and creates a vacuum in the cooling system. the wrong water pump will cause engine overheating.
This causes the vacuum valve to open and coolant in A quick test to determine if the pump is working is
the reserve/overflow tank to be drawn through its to check if the heater warms properly. A defective
connecting hose into radiator. If the vacuum valve is water pump will not be able to circulate heated cool-
stuck shut, the radiator hoses will collapse on coolant through the long heater hose to the heater core.
down.
A rubber gasket seals radiator filler neck. This is COOLING SYSTEM HOSES
done to maintain vacuum during coolant cool-down Rubber hoses route coolant to and from the radia-
and to prevent leakage when system is under pres- tor, intake manifold and heater core. Radiator lower
sure. hoses are spring-reinforced to prevent collapse from
water pump suction at moderate and high engine
WATER PUMPS speeds.
A centrifugal water pump circulates coolant
WARNING: CONSTANT TENSION HOSE CLAMPS
through the water jackets, passages, intake manifold,
ARE USED ON MOST COOLING SYSTEM HOSES.
radiator core, cooling system hoses and heater core.
WHEN REMOVING OR INSTALLING, USE ONLY
The pump is driven from the engine crankshaft by a
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
drive belt on all engines.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
The water pump impeller is pressed onto the rear
6094) (Fig. 7). SNAP-ON CLAMP TOOL (NUMBER
of a shaft that rotates in bearings pressed into the
HPC-20) MAY BE USED FOR LARGER CLAMPS.
housing. The housing has a small hole to allow seep-
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
age to escape. The water pump seals are lubricated
ING CONSTANT TENSION CLAMPS.
by the antifreeze in the coolant mixture. No addi-
tional lubrication is necessary.

CAUTION: All engines are equipped with a reverse
(counter-clockwise) rotating water pump and vis-

LETTER HOSE
CLAMP NUMBER/ CLAMPCONSTANT
TYPICAL HOSE 6094
LOCA-
TENSION
TION TOOL
CLAMP TYPICAL HOSE HOSECLAMP THERMOSTATIC FAN DRIVE
VISCOUS
SPRING MOUNTING HUB

CAUTION: A number or letter is stamped into the Ordinary worm gear type hose clamps (when
tongue of constant tension clamps (Fig. 8). If equipped) can be removed with a straight screw-
replacement is necessary, use only an original driver or a hex socket. To prevent damage to
equipment clamp with matching number or letter. hoses or clamps, the hose clamps should be
tightened to 4 N·m (34 in. lbs.) torque. Do not
over tighten hose clamps.

VISCOUS FAN DRIVE
NOTE: Also refer to Cooling System Fans.

The thermal viscous fan drive is a silicone-fluid-
filled coupling used to connect the fan blades to
either the engine or the water pump shaft. The cou-
pling 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.
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. 9). This spring coil
Fig. 7 Hose Clamp Tool—Typical 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.

Fig. 9 Typical Viscous Fan Drive
Fig. 8 Clamp Number/Letter Location
Only when sufficient heat is present, will the vis-
Inspect the hoses at regular intervals. Replace
cous fan drive engage. This is when the air flowing
hoses that are cracked, feel brittle when squeezed, or
through the radiator core causes a reaction to the
swell excessively when the system is pressurized.
bimetallic coil. It then increases fan speed to provide
For all vehicles: In areas where specific routing
the necessary additional engine cooling.
clamps are not provided, be sure that hoses are posi-
Once the engine has cooled, the radiator discharge
tioned with sufficient clearance. Check clearance
temperature will drop. The bimetallic coil again
from exhaust manifolds and pipe, fan blades, drive
reacts and the fan speed is reduced to the previous
belts and sway bars. Improperly positioned hoses can
disengaged speed.
be damaged, resulting in coolant loss and engine
overheating.

POWER
RIGHT
FENDER
DISTRIBUTION
CENTER BATTERY

CAUTION: 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 overheat-
ing.

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.

NOISE
It is normal for fan noise to be louder (roar-
ing) when:
• The underhood temperature is above the engage-
ment point for the viscous drive coupling. This may Fig. 10 Power Distribution Center (PDC)
occur when ambient (outside air temperature) is very DIAGNOSIS AND TESTING
high.
• Engine loads and temperatures are high such as ON-BOARD DIAGNOSTICS (OBD)
when towing a trailer.
• Cool silicone fluid within the fan drive unit is COOLING SYSTEM RELATED DIAGNOSTICS
being redistributed back to its normal disengaged The Powertrain Control Module (PCM) has been
(warm) position. This can occur during the first 15 programmed to monitor the certain following cooling
seconds to one minute after engine start-up on a cold system components:
engine. • If the engine has remained cool for too long a
period, such as with a stuck open thermostat, a Diag-
AUXILIARY ELECTRIC COOLING FAN nostic Trouble Code (DTC) can be set.
Models equipped with a 4.0L 6-cylinder engine may • If an open or shorted condition has developed in
also have an auxiliary electrical cooling fan. This is the relay circuit controlling the electric radiator fan,
with models that have air conditioning and/or heavy a Diagnostic Trouble Code (DTC) can be set.
duty cooling. The fan is controlled by the cooling fan If the problem is sensed in a monitored circuit
relay, which is located in the power distribution cen- often enough to indicate an actual problem, a DTC is
ter (PDC) (Fig. 10). For the location of relay within stored. The DTC will be stored in the PCM memory
the PDC, refer to the label on PDC cover. for eventual display to the service technician. (Refer
When coolant temperature reaches approximately to Group 25, Emission Control Systems for proper
103°C (218°F), or when air conditioning is requested, procedures)
the powertrain control module (PCM) provides a
ground path for the fan relay. This ground is pro- ACCESSING DIAGNOSTIC TROUBLE CODES
vided to the cooling fan relay through pin C2 of PCM To read DTC’s and to obtain cooling system data,
connector C3. Battery voltage is then applied to the refer to Group 25, Emission Control Systems for
fan through the relay. When coolant temperature proper procedures.
drops below approximately 98°C (209°F), the PCM
opens the ground path to the relay. This will prevent DRB SCAN TOOL
the cooling fan from being energized. For operation of the DRB scan tool, refer to the
appropriate Powertrain Diagnostic Procedures ser-
vice manual.

DIAGNOSIS AND TESTING (Continued)
ENGINE ACCESSORY DRIVE BELTS
BELT DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 11), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) are not nor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 11). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to the Serpentine Drive Belt Diagnosis
charts for further belt diagnosis.

Fig. 11 Serpentine Belt Wear Patterns

SERPENTINE BELT DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (One or more ribs has 1. Foreign objects imbedded in pulley 1. Remove foreign objects from pulley
separated from belt body) grooves. grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove tips 4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of insufficient 1. Adjust tension
tension
2. Belt or pulley exposed to substance 2. Replace belt and clean pulleys
that has reduced friction (belt dressing,
oil, ethylene glycol)
3. Driven component bearing failure 3. Replace faulty component or bearing
(seizure)
4. Belt glazed or hardened from heat 4. Replace belt.
and excessive slippage
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove
2. Pulley groove tip has worn away 2. Replace belt
rubber to tensile member

7 - 10 COOLING SYSTEM XJ

ЉGROOVE JUMPING” 1. Belt tension either too low or too 1. Adjust belt tension
(Belt does not maintain correct high
position on pulley) 2. Pulley(s) not within design 2. Replace pulley(s)
tolerance
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN 1. Excessive tension 1. Replace belt and adjust tension to
(Note: Identify and correct problem specification
before new belt is installed) 2. Tensile member damaged during 2. Replace belt
belt installation
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component and
belt
NOISE 1. Belt slippage 1. Adjust belt
(Objectional squeal, squeak, or 2. Bearing noise 2. Locate and repair
rumble is heard or felt while drive belt 3. Belt misalignment 3. Align belt/pulley(s)
is in operation) 4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced 5. Locate defective driven component
vibration and repair
6. System resonant frequency 6. Vary belt tension within
induced vibration specifications.
TENSION SHEETING FABRIC 1. Tension sheeting contacting 1. Correct rubbing condition
FAILURE stationary object
(Woven fabric on outside,
2. Excessive heat causing woven 2. Replace belt
circumference of belt has cracked or
fabric to age
separated from body of belt)
3. Tension sheeting splice has 3. Replace belt
fractured
CORD EDGE FAILURE 1. Excessive tension 1. Adjust belt tension
(Tensile member exposed at edges of 2. Belt contacting stationary object 2. Replace belt
belt or separated from belt body) 3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between 4. Replace belt and adjust tension to
tensile member and rubber matrix specifications

PRELIMINARY CHECKS TRAILER TOWING:
Consult Trailer Towing section of owners manual.
ENGINE COOLING SYSTEM OVERHEATING Do not exceed limits.
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as AIR CONDITIONING; ADD-ON OR AFTER MARKET:
the following may be the cause: A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE, installed. If not, maximum cooling system compo-
SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC
nents should be installed for model involved per
JAMS, HIGH SPEED OR STEEP GRADES.
manufacturer’s specifications.
Driving techniques that avoid overheating are:
• Idle with A/C off when temperature gauge is at RECENT SERVICE OR ACCIDENT REPAIR:
end of normal range.
Determine if any recent service has been per-
• Increasing engine speed for more air flow is rec- formed on vehicle that may effect cooling system.
ommended. This may be:

XJ COOLING SYSTEM 7 - 11
• Engine adjustments (incorrect timing) NOTE: If investigation reveals none of the previous
• Slipping engine accessory drive belt(s) items as a cause for an engine overheating com-
• Brakes (possibly dragging) plaint, refer to following Cooling System Diagnosis
• Changed parts. Incorrect water pump or pump charts.
rotating in wrong direction due to belt not correctly
routed These charts are to be used as a quick-reference
• Reconditioned radiator or cooling system refill- only. Refer to the group text for information.
ing (possibly under filled or air trapped in system).

COOLING SYSTEM DIAGNOSIS
TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On-Board Diagnostics in
LOW (DTC) number 17 been set indicating the service manual text. Replace
a stuck open engine thermostat? thermostat if necessary. If a
Diagnostic Trouble Code (DTC)
number 17 has not been set, the
problem may be with the temperature
gauge.
2. Is the temperature gauge (if 2. Check the engine temperature
equipped) connected to the sensor connector in the engine
temperature gauge coolant sensor on compartment. Refer to Group 8E.
the engine? Repair as necessary.
3. Is the temperature gauge (if 3. Check gauge operation. Refer to
equipped) operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold ambient 4. Check coolant level in the coolant
temperatures accompanied with poor reserve/overflow tank and the
heater performance. radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual text
for WARNINGS and precautions
before removing the radiator cap.
5. Improper operation of internal 5. Inspect heater and repair as
heater doors or heater controls. necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.
TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep hill is1. This may be a temporary condition
HIGH OR ENGINE COOLANT being climbed, vehicle is operated in and repair is not necessary. Turn off
WARNING LAMP ILLUMINATES. slow moving traffic, or engine is being the air conditioning and attempt to
COOLANT MAY OR MAY NOT BE idled with very high ambient (outside) drive the vehicle without any of the
LOST OR LEAKING FROM temperatures and the air conditioning previous conditions. Observe the
COOLING SYSTEM is on. Higher altitudes could aggravate temperature gauge. The gauge
these conditions. should return to the normal range. If
the gauge does not return to normal
range, determine the cause for
overheating and repair. Refer to
POSSIBLE CAUSES (numbers 2
through 20).
2. Is temperature gauge (if equipped) 2. Check gauge. Refer to Group 8E.
reading correctly? Repair as necessary.
3. Is temperature warning lamp (if 3. Check warning lamp operation.
equipped) illuminating unnecessarily? Refer to Group 8E. Repair as
necessary.
4. Coolant low in coolant reserve/ 4. Check for coolant leaks and repair
overflow tank and radiator. as necessary. Refer to Testing
Cooling System For Leaks in this
group.
5. Pressure cap not installed tightly. If 5. Tighten cap.
cap is loose, boiling point of coolant
will be lowered. Also refer to the
following step 6.
6. Poor seals at 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.

COOLING SYSTEM DIAGNOSIS


TEMPERATURE GAUGE READS 7. Coolant level low in radiator but not
7. (a) Check condition of radiator cap
HIGH OR ENGINE COOLANT in coolant reserve/overflow tank. This and cap seals. Refer to Radiator Cap
WARNING LAMP ILLUMINATES. means the radiator is not drawing in this group. Replace cap if necessary.
COOLANT MAY OR MAY NOT BE coolant from the coolant reserve/ (b) Check condition of radiator filler
LOST OR LEAKING FROM COOLING overflow tank as the engine cools. neck. If neck is bent or damaged,
SYTEM (Continued) As the engine cools, a vacuum is replace radiator.
formed in the cooling system of the (c) Check the condition of the hose
engine and radiator. If radiator cap from the radiator to the coolant tank. It
seals are defective, or cooling system should fit tight at both ends without any
has leaks, a vacuum can not be kinks or tears. Replace hose if
formed. necessary.
(d) Check coolant reserve/overflow
tank and tank hose for blockage.
Repair as necessary.
8. Freeze point of antifreeze not 8. Check antifreeze. Refer to Coolant
correct. Mixture may be too rich. section of this group. Adjust antifreeze-
to-water ratio as required.
9. Coolant not flowing through system. 9. 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 reason for lack of
flow and repair as necessary.
10. Radiator or A/C condenser fins are 10. Clean insects or debris. Refer to
dirty or clogged. Radiator Cleaning in this group.
11. Radiator core is corroded or 11. Have radiator re-cored or replaced.
plugged.
12. Aftermarket A/C installed without 12. Install proper radiator.
proper radiator.
13. Fuel or ignition system problems. 13. Refer to Fuel and Ignition System
groups for diagnosis. Also refer to the
appropriate Powertrain Diagnostic
Procedures service manual for
operation of the DRB scan tool.
14. Dragging brakes. 14. Check and correct as necessary.
Refer to Group 5, Brakes in this
manual text.
15. Bug screen is being used reducing 15. Remove bug screen.
airflow.
16. Thermostat partially or completely 16. Check thermostat operation and
shut. This is more prevalent on high replace as necessary. Refer to
mileage vehicles. Thermostats in this group.
17. Thermal viscous fan drive not 17. Check fan drive operation and
operating properly. replace if necessary. Refer to Viscous
Fan Drive in this group.
18. Electric cooling fan not operating 18. Check electric fan operation and
properly (XJ models with 4.0L engine repair as necessary. Refer to Auxiliary
equipped with heavy duty cooling Electric Cooling Fan-XJ Models with
and/or air conditioning). 4.0L 6-cylinder engine in the manual
text.

COOLING SYSTEM DIAGNOSIS (CONT.)


TEMPERATURE GAUGE READS 19. Cylinder head gasket leaking 19. Check for cylinder head gasket
HIGH OR ENGINE COOLANT leaks. Refer to Testing Cooling System
WARNING LAMP ILLUMINATES. for Leaks in this group. For repair refer
COOLANT MAY OR MAY NOT BE to Group 9, Engines.
LOST OR LEAKING FROM COOLING
SYSTEM (Continued)
20. Heater core leaking. 20. Check heater core for leaks. Refer
to Group 24, Heating and Air
Conditioning. Repair as necessary.
TEMPERATURE GUAGE READING IS 1. On XJ models equipped with a 4.0L 1. A normal condition. No correction is
INCONSISTENT (FLUCTUATES, 6-cylinder engine, heavy duty cooling necessary. If gauge cycling is going
CCLES OR IS ERRACTIC) and/or air conditioning, the gauge may into the hot zone, check electric fan
cycle up and down. This is due to the operation and repair as necessary.
cycling of the electric radiator fan. Refer to Auxiliary Electric Cooling
Fan-XJ Models with 4.0L 6-cylinder
engine in the manual text.
2. During cold weather operation, with 2. A normal condition. No correction is
the heater blower in the high position, necessary.
the gauge reading may drop slightly.
3. Temperature gauge or engine 3. Check operation of gauge and repair
mounted gauge sensor defective or if necessary. Refer to Group 8E,
shorted. Also, corroded or loose wiring Instrument Panel and Gauges.
in this circuit.
4. Gauge reading rises when vehicle is 4. A normal condition. No correction is
brought to a stop after heavy use necessary. Gauge reading should
(engine still running). return to normal range after vehicle is
driven.
5. Gauge reading high after restarting a 5. A normal condition. No correction is
warmed-up (hot) engine. necessary. The gauge should return to
normal range after a few minutes of
engine operation.
6. Coolant level low in radiator (air will 6. Check and correct coolant leaks.
build up in the cooling system causing Refer to Testing Cooling Sytem for
the thermostat to open late). Leaks in this group.
7. Cylinder head gasket leaking 7. (a) Check for cylinder head gasket
allowing exhaust gas to enter cooling leaks with a commercially available
system causing thermostat to open late. Block Leak Tester. Repair as
necessary.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.
8. Water pump impeller loose on shaft. 8. Check water pump and replace as
necessary. Refer to Water Pumps in
this group.
9. Loose accessory drive belt (water 9. Refer to Engine Accessory Drive
pump slipping). Belts in this group. Check and correct
as necessary.
10. Air leak on the suction side of water 10. Locate leak and repair as
pump allows air to build up in cooling necessary.
system causing thermostat to open late.



PRESSURE CAP IS BLOWING OFF 1. Pressure relief valve in radiator cap 1. Check condition of radiator cap and
STEAM AND/OR COOLANT TO is defective. cap seals. Refer to Radiator Caps in
COOLANT TANK. TEMPERATURE this group. Replace cap as necessary.
GAUGE READING MAY BE ABOVE
NORMAL BUT NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN COOLANT
RESERVE/OVERFLOW TANK
COOLANT LOSS TO THE GROUND 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
WITHOUT PRESSURE CAP system hoses, water pump or engine. necessary. Refer to Testing Cooling
BLOWOFF. GAUGE IS READING System for Leaks in this group.
HIGH OR HOT
DETONATION OR PREIGNITION 1. Engine overheating. 1. Check reason for overheating and
(NOT CAUSED BY IGNITION repair as necessary.
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
2. Freeze point of antifreeze not 2. Check antifreeze. Refer to the
correct. Mixture is too rich or too lean. Coolant section in this group. Adjust
antifreeze-to-water ratio as required.

HOSE OR HOSES COLLAPSE WHEN 1. Vacuum created in cooling system on 1. (a) Radiator cap relief valve stuck.
ENGINE IS COOLING engine cool-down is not being relieved Refer to Radiator Cap in this group.
through coolant reserve/overflow Replace if necessary.
system. (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.
ELECTRIC RADIATOR FAN RUNS 1. Fan relay, powertrain control module 1. Refer to Auxiliary Electric Cooling
ALL THE TIME (XJ MODELS WITH (PCM) or engine coolant temperature Fan-XJ Models with 4.0L 6-Cylinder
4.0L ENGINE EQUIPPED WITH sensor defective. engine in the manual text. Repair as
HEAVY DUTY COOLING AND/OR AIR necessary. Also refer to appropriate
CONDITIONING ONLY) Powertrain Diagnostic Procedures
service manual for operation of the
DRB scan tool.
ELECTRIC RADIATOR FAN WILL NOT 1. Fan motor defective. 1. Refer to Auxiliary Electric Cooling
RUN (XJ MODELS WITH 4.0L Fan-XJ Models with 4.0L 6-Cylinder
ENGINE EQUIPPED WITH HEAVY engine in the manual text. Repair as
DUTY COOLING AND/OR AIR necessary.
CONDITIONING ONLY) GAUGE 2. Fan relay, powertrain control module 2. Refer to Auxiliary Electric Cooling
READING HIGH OR HOT (PCM) or engine coolant temperature Fan-XJ Models with 4.0L 6-Cylinder
sensor defective. engine in the manual text. Repair as
necessary. Also refer to the appropriate
Powertrain Diagnostic Procedures
service manual for operation of the
DRB scan tool
3. Blown fuse in power distribution 3. Determine reason for blown fuse
center (PDC). and repair as necessary.



NOISY FAN 1. Fan blades loose. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a surrounding 2. Locate point of fan blade contact
object. and repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or clean
conditioning condenser. debris or insects from radiator or A/C
condenser.
4. Electric fan motor defective (if 4. Replace electric fan motor. Refer to
equipped). Auxiliary Electric Cooling Fan-XJ
Models with 4.0L 6-Cylinder engine in
the manual text.
5. Thermal viscous fan drive has 5. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan
Drive in this group.
6. A certain amount of fan noise 6. Refer to Viscous Fan Drive in this
(roaring) may be evident on models group for an explanation of normal fan
equipped with a thermal viscous fan noise.
drive. Some of this noise is normal.
INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
PERFORMANCE (COOLING SYSTEM restricted, obstructed or dirty (insects, necessary. Refer to Radiator Cleaning
SUSPECTED) leaves etc.). in this group.
2. Electric radiator fan not operating 2. Refer to Auxiliary Electric Cooling
when A/C is operated (if equipped with Fan-XJ Models with 4.0L 6-Cylinder
electric fan). engine in the manual text. Repair as
necessary.
3. Thermal viscous fan drive is 3. Refer to Viscous Fan Drive for
freewheeling. diagnosis. Repair as necessary.
4. Engine is overheating (heat may be 4. Correct overheating condition. Refer
transferred from radiator to A/C to text in Group 7, Cooling.
condenser. High underhood
temperatures due to engine overheating
may also transfer heat to A/C
components).
5. Some models with certain engines 5. Check for missing or damaged air
are equipped with air seals at the seals and repair as necessary.
radiator and/or A/C condenser. If these
seals are missing or damaged, not
enough air flow will be pulled through
the radiator and A/C condenser.
INADEQUATE HEATER 1. Has a diagnostic trouble code (DTC) 1. Refer to On-Board Diagnostics in
PERFORMANCE. THERMOSTAT number 17 been set? the manual text and replace thermostat
FAILED IN OPEN POSITION if necessary.
2. Coolant level low. 2. Refer to Testing Cooling System for
Leaks in the manual text. Repair as
necessary.
3. Obstructions in heater hose fittings at 3. Remove heater hoses at both ends
engine. and check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.



INADEQUATE HEATER 5. Some models with certain engines 5. Refer to Group 24, Heating and
PERFORMANCE. THERMOSTAT are equipped with a water control Air Conditioning for diagnosis. Repair
FAILED IN OPEN POSITION valve located on one of the heater as necessary.
(Continued) hoses. This valve may be defective.
6. Water pump is not pumping water 6. Refer to Water Pumps in this
to heater core. When the engine is group. Repair as necessary. If a
fully warmed up, both heater hoses slipping belt is detected, refer to
should be hot to the touch. If only Engine Accessory Drive Belts in this
one of the hoses is hot, the water group. Repair as necessary.
pump may not be operating correctly.
The accessory drive belt may also be
slipping causing poor water pump
operation.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and
certain drive line components. One or replace or repair as necessary.
more of these shields may be
missing.
2. Is temperature gauge reading 2. Refer to the previous Temperature
above the normal range? Gauge Reads High in these
Diagnosis Charts. Repair as
necessary.
3. Is cooling fan operating correctly? 3. Refer to Cooling System Fan in
this group for diagnosis. Repair as
necessary.
4. Has undercoating been applied to 4. Clean undercoating as necessary.
any unnecessary component?
5. Engine may be running rich 5. Refer to the DRB scan tool and
causing the catalytic convertor to the appropriate Powertrain
overheat. Diagnostic Procedures service
manual. Repair as necessary.
POOR DRIVEABILITY 1. For proper driveability, good 1. Refer to On-Board Diagnostics in
(THERMOSTAT POSSIBLY STUCK vehicle emissions and for preventing this group. DTC’s may also be
OPEN) GAUGE READING MAY BE build-up of engine oil sludge, the checked using the DRB scan tool.
LOW thermostat must be operating Refer to the proper Powertrain
properly. Has a diagnostic trouble Diagnostics Procedures service
code (DTC) number 17 been set? manual for checking the thermostat
using the DRB scan tool. Replace
thermostat if necessary.
STEAM IS COMING FROM FRONT 1. During wet weather, moisture 1. Occasional steam emitting from
OF VEHICLE NEAR GRILL AREA (snow, ice or rain condensation) on this area is normal. No repair is
WHEN WEATHER IS WET, ENGINE the radiator will evaporate when the necessary.
IS WARMED UP AND RUNNING, thermostat opens. This opening
AND VEHICLE IS STATIONARY. allows heated water into the radiator.
TEMPERATURE GAUGE IS IN When the moisture contacts the hot
NORMAL RANGE radiator, steam may be emitted. This
usually occurs in cold weather with
no fan or airflow to blow it away.



COOLANT COLOR 1. Coolant color is not necessarily an 1. Refer to Coolant in this group for
indication of adequate corrosion or antifreeze tests. Adjust antifreeze-to-
temperature protection. Do not rely water ratio as necessary.
on coolant color for determining
condition of coolant.
COOLANT LEVEL CHANGES IN 1. Level changes are to be expected 1. A normal condition. No repair is
COOLANT RESERVE/OVERFLOW as coolant volume fluctuates with necessary.
TANK. TEMPERATURE GAUGE IS engine temperature. If the level in the
IN NORMAL RANGE tank was between the FULL and ADD
marks at normal engine operating
temperature, the level should return
to within that range after operation at
elevated temperatures.


TYPICAL COOLINGTESTER
PRESSURE SYTEM
TYPICAL BLACK
LIGHT TOOL

RADIATOR COOLANT FLOW CHECK WARNING: HOT, PRESSURIZED COOLANT CAN
The following procedure will determine if coolant is CAUSE INJURY BY SCALDING.
flowing through the cooling system.
If engine is cold, idle engine until normal operating Carefully remove the radiator pressure cap from
temperature is reached. Then feel the upper radiator the filler neck and check the coolant level. Push
hose. If hose is hot, the thermostat is open and water down on the cap to disengage it from the stop tabs.
is circulating through cooling system. Wipe the inner part of the filler neck and examine
the lower inside sealing seat for nicks, cracks, paint,
TESTING COOLING SYSTEM FOR LEAKS dirt and solder residue. Inspect the reserve/overflow
tank tube for internal obstructions. Insert a wire
ULTRAVIOLET LIGHT METHOD through the tube to be sure it is not obstructed.
All Jeep models have a leak detection additive Inspect the cams on the outside part of the filler
added to the cooling system before they leave the fac- neck. If the cams are bent, seating of pressure cap
tory. The additive is highly visible under ultraviolet valve and tester seal will be affected. Replace cap if
light (black light). If the factory original coolant has cams are bent.
been drained, pour one ounce of additive into the Attach pressure tester 7700 (or an equivalent) to
cooling system. The additive is available through the the radiator filler neck (Fig. 13).
part’s department. Place the heater control unit in
HEAT position. Start and operate the engine until
the radiator upper hose is warm to the touch. Aim
the commercially 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 along with a pressure
tester to determine if any external leaks exist (Fig.
12).

Fig. 13 Pressurizing System—Typical
Operate the tester pump to apply 124 kPa (18 psi)
pressure to the system. If the hoses enlarge exces-
sively or bulge while testing, replace as necessary.
Observe the gauge pointer and determine the condi-
tion of the cooling system according to the following
criteria:
• Holds Steady: If the pointer remains steady for
two minutes, there are no serious coolant leaks in
the system. However, there could be an internal leak
that does not appear with normal system test pres-
sure. Inspect for interior leakage or do the Internal
Leakage Test. Do this if it is certain that coolant is
being lost and no leaks can be detected.
• Drops Slowly: Shows a small leak or seepage is
occurring. Examine all connections for seepage or
Fig. 12 Leak Detection Using Black Light—Typical slight leakage with a flashlight. Inspect the radiator,
PRESSURE TESTER METHOD hoses, gasket edges and heater. Seal any small leak
The engine should be at the normal operating tem- holes with a Sealer Lubricant or equivalent. Repair
perature. Recheck the system cold if the cause of leak holes and reinspect the system with pressure
coolant loss is not located during warm engine exam- applied.
ination. • Drops Quickly: Shows that a serious leakage is
occurring. Examine the system for serious external

leakage. If no leaks are visible, inspect for internal Drain sufficient coolant to allow for thermostat
leakage. Large radiator leak holes should be repaired removal. Refer to Thermostat Replacement. Discon-
by a reputable radiator repair shop. nect the water pump drive belt.
Disconnect the upper radiator hose from the ther-
INTERNAL LEAKAGE INSPECTION mostat housing. Remove the housing and thermostat.
Remove the engine oil pan drain plug and drain a Install the thermostat housing.
small amount of engine oil. Coolant, being heavier Add coolant to the radiator to bring the level to
than engine oil, will drain first. Another way of test- within 6.3 mm (1/4 in) of the top of the thermostat
ing is to operate the engine and check for water glob- housing.
ules on the engine oil dipstick. Also inspect the
automatic transmission oil dipstick for water glob- CAUTION: Avoid overheating. Do not operate the
ules. Inspect the automatic transmission fluid cooler engine for an excessive period of time. Open the
for leakage. Operate the engine without the pressure draincock immediately after the test to eliminate
cap on the radiator until thermostat opens. boil over of coolant.
Attach a pressure tester to the filler neck. If pres-
sure builds up quickly, a leak exists as a result of a Start the engine and accelerate rapidly three times
faulty cylinder head gasket or crack in the engine. (to approximately 3000 rpm) while observing the
Repair as necessary. coolant. If internal engine combustion gases are leak-
ing into the cooling system, bubbles will appear in
WARNING: DO NOT ALLOW PRESSURE TO the coolant. If bubbles do not appear, there is no
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF. internal combustion gas leakage.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE VISCOUS FAN DRIVE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE. LEAKS
Viscous fan drive operation is not affected by small
If there is no immediate pressure increase, pump oil stains near the drive bearing. If leakage appears
the pressure tester until the indicated pressure is excessive, replace the fan drive unit.
within the system range. Vibration of the gauge
pointer indicates compression or combustion leakage TESTING
into the cooling system. If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
WARNING: DO NOT DISCONNECT THE SPARK spun by hand), replace the fan drive. This spin test
PLUG WIRES WHILE THE ENGINE IS OPERATING. 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-
CAUTION: Do not operate the engine with a spark sively high coolant temperature.
plug shorted for more than a minute. The catalytic
converter may be damaged. WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
Isolate the compression leak by shorting each
spark plug to the cylinder block. The gauge pointer (1) Drill a 3.18-mm (1/8-in) diameter hole in the
should stop or decrease vibration when spark plug top center of the fan shroud.
for leaking cylinder is shorted. This happens because (2) Obtain a dial thermometer with an 8 inch stem
of the absence of combustion pressure. (or equivalent). It should have a range of -18°-to-
105°C (0°-to-220° F). Insert thermometer through the
COMBUSTION LEAKAGE TEST (WITHOUT hole in the shroud. Be sure that there is adequate
PRESSURE TESTER) clearance from the fan blades.
DO NOT WASTE reusable coolant. If the solution (3) Connect a tachometer and an engine ignition
is clean, drain the coolant into a clean container for timing light (timing light is to be used as a strobe
reuse. light).
(4) Block the air flow through the radiator. Secure
WARNING: DO NOT REMOVE THE CYLINDER
a sheet of plastic in front of the radiator (or air con-
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
ditioner condenser). Use tape at the top to secure the
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
plastic and be sure that the air flow is blocked.
PRESSURE. SERIOUS BURNS FROM COOLANT
(5) Be sure that the air conditioner (if equipped) is
CAN OCCUR.
turned off.

VACUUM VENT VALVE (SHOWN IN SEAL-
ING POSITION) PRESSURE RATING SEAL
PRESSURE VALVE
FILLER NECK

WARNING: USE EXTREME CAUTION WHEN THE SHOULD NOT BE REMOVED WHILE THE SYSTEM
ENGINE IS OPERATING. DO NOT STAND IN A IS HOT AND/OR UNDER PRESSURE.
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 88° C (190° F).
Fan drive engagement should have started to occur
at between 74° to 82° C (165° to 180° F). Engage-
ment is distinguishable by a definite increase in fan
flow noise (roaring). The timing light also will indi-
cate an increase in the speed of the fan.
(7) When the air temperature reaches 88° C (190°
F), remove the plastic sheet. Fan drive disengage-
ment should have started to occur at between 57° to
79° C (135° to 175° F). A definite decrease of fan
flow noise (roaring) should be noticed. If not, replace
the defective viscous fan drive unit.

AUXILIARY ELECTRIC COOLING FAN
ELECTRIC COOLING FAN AND RELAY
DIAGNOSIS

NOTE: Refer to Electrical Group 8W for electric
cooling fan and relay circuit schematic.

The powertrain control module (PCM) will enter a
diagnostic trouble code (DTC) in memory if it detects
a problem in the auxiliary cooling fan relay or circuit. Fig. 14 Radiator Pressure Cap
Refer to Group 25, Emission Control Systems for cor-
There is no need to remove the radiator cap
rect DTC retrieval procedures.
except for the following purposes:
If the electric cooling fan is inoperative, check fuse
(1) To check and adjust antifreeze freeze point.
#11 (20A) in junction block and fuse #5 (40A maxi-
(2) To refill system with new antifreeze.
fuse) in the Power Distribution Center (PDC) with a
(3) For conducting service procedures.
12 volt test lamp or DVOM. If fuses are o.k., refer to
(4) When checking for vacuum leaks.
Group 8W for electric cooling fan and relay circuit
schematic. WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE
RADIATOR CAP-TO-FILLER NECK SEAL— REMOVING RADIATOR CAP. WITH A RAG,
PRESSURE RELIEF CHECK SQUEEZE RADIATOR UPPER HOSE TO CHECK IF
With radiator cap installed on filler neck, remove SYSTEM IS UNDER PRESSURE. PLACE A RAG
coolant reserve/ overflow tank hose from nipple on OVER THE CAP AND WITHOUT PUSHING DOWN,
filler neck. Connect a hand operated vacuum pump ROTATE CAP COUNTER-CLOCKWISE TO THE
to nipple. Operate pump until a reading of 47-to-61 FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH
kPa (14- to-18 in. Hg) appears on gauge. If the read- OVERFLOW HOSE INTO COOLANT RESERVE/
ing stays steady, or drops slightly and then remains OVERFLOW TANK. SQUEEZE RADIATOR UPPER
steady, the pressure valve seal is good. Replace radi- HOSE TO DETERMINE WHEN PRESSURE HAS
ator cap if reading does not hold. BEEN RELEASED. WHEN COOLANT AND STEAM
STOP BEING PUSHED INTO TANK AND SYSTEM
WARNING: THE WARNING WORDS -DO NOT OPEN PRESSURE DROPS, REMOVE RADIATOR CAP
HOT- ON THE RADIATOR PRESSURE CAP (Fig. 14) COMPLETELY.
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP

Exj 7

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