Jeep Cherokee (XJ): Thermostat. Radiator-2.5L. Radiator-4.0L

Thermostat

REMOVAL

WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED.

SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

DO NOT WASTE reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.

(1) Drain the coolant from the radiator until the level is below the thermostat housing.

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES.

WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS.

ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 11). If replacement is necessary, use only an original equipment clamp with matching number or letter.

(2) Remove radiator upper hose and heater hose at thermostat housing.

(3) Disconnect wiring connector at engine coolant temperature sensor.

(4) Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat (Fig. 32).

Discard old gasket.

(5) Clean the gasket mating surfaces.

INSTALLATION

(1) Install the replacement thermostat so that the pellet, which is encircled by a coil spring, faces the engine. All thermostats are marked on the outer flange to indicate the proper installed position.

(a) Observe the recess groove in the engine cylinder head (Fig. 33).

(b) Position thermostat into this groove with arrow and air bleed hole on outer flange pointing up.

Fig. 32 Thermostat Removal/Installation
Fig. 32 Thermostat Removal/Installation

1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT

Fig. 33 Thermostat Recess
Fig. 33 Thermostat Recess

1 - GROOVE

(2) Install replacement gasket and thermostat housing.

CAUTION: Tightening the thermostat housing unevenly or with the thermostat out of its recess may result in a cracked housing.

(3) Tighten the housing bolts to 20 N·m (15 ft. lbs.) torque.

(4) Install hoses to thermostat housing.

(5) Install electrical connector to coolant temperature sensor.

(6) Be sure that the radiator draincock is tightly closed. Fill the cooling system to the correct level with the required coolant mixture. Refer to Refilling Cooling System in this group.

(7) Start and warm the engine. Check for leaks.

Radiator-2.5L

WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED.

SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse.

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES.

WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS.

ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 11). If replacement is necessary, use only an original equipment clamp with matching number or letter.

REMOVAL

(1) Disconnect battery negative cable.

(2) Observe the previous WARNINGS.

(3) Remove radiator pressure cap.

(4) For access to radiator draincock, remove radiator grill mounting screws and remove grill. Refer to Group 23, Body for procedures.

(5) Attach one end of a 24 inch long X 1/4 inch ID hose to the radiator petcock (Fig. 34). Put the other end into a clean container. Open petcock and drain radiator.

(6) Detach power steering fluid reservoir from fan shroud and lay aside.

(7) Disconnect electric cooling fan electrical connector, if equipped.

Fig. 34 Radiator Petcock-Typical
Fig. 34 Radiator Petcock-Typical

1 - RADIATOR PETCOCK

(8) Disconnect CRS hose from radiator filler neck and remove from shroud retaining loops.

(9) Remove the four (4) viscous fan/drive assembly nuts from the water pump pulley and remove fan/ drive assy.

(10) Remove the four (4) fan shroud to core support mounting screws.

(11) Remove the electric fan (if equipped) and shroud assembly from the vehicle (Fig. 36).

(12) Remove radiator upper crossmember (Fig. 36).

(13) If equipped with air conditioning, separate radiator from condenser by removing condenser-to-radiator mounting brackets (Fig. 35).

(14) Disconnect upper and lower radiator hoses.

(15) If equipped, disconnect and plug automatic transmission fluid cooler lines. Quick Connect Fitting Release Tool 6935 may be needed. If equipped with remote transmission cooler, remove line to cooler from bracket at bottom of radiator.

(16) Lift radiator straight up and out of engine compartment taking care not to damage fins.

(17) If radiator is to be replaced, be sure to remove and transfer any components not included with replacement radiator.

INSTALLATION

The radiator is supplied with two alignment dowels (Fig. 41). They are located on the bottom tank and fit into rubber grommets in the radiator lower crossmember.

Fig. 35 Condenser-to-Radiator Mounting Brackets
Fig. 35 Condenser-to-Radiator Mounting Brackets

1 - CONDENSER TO RADIATOR MOUNTING BRACKETS

(1) Lower radiator into engine compartment. Position alignment dowels into rubber grommets in radiator lower crossmember (Fig. 41).

(2) If equipped with air conditioning, attach condenser to radiator with mounting brackets (Fig. 35).

(3) Install radiator upper crossmember and four mounting bolts.

(4) Install radiator upper crossmember-to-isolator nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If isolator-to-radiator nuts had been removed, tighten them to 5 N·m (47 in. lbs.) torque.

(5) Connect radiator upper and lower hoses.

(6) If equipped, connect automatic transmission fluid cooler lines. If equipped with remote cooler, attach cooler line to bracket at bottom of radiator.

(7) Install electric fan (if equipped) and shroud assembly.. Insert alignment tabs at bottom of fan shroud into slots in bracket at bottom of radiator.

Tighten mounting bolts to 3 N·m (31 in. lbs.) torque.

(8) Connect electric cooling fan electrical connector.

(9) Install power steering reservoir to fan shroud.

(10) Install grill.

(11) Connect battery negative cable.

Fig. 36 Radiator Removal/Installation-2.5L Engines
Fig. 36 Radiator Removal/Installation-2.5L Engines

1 - ELECTRIC FAN/SHROUD ASSEMBLY
2 - UPPER CROSSMEMBER
3 - ISOLATOR
4 - RADIATOR
5 - LOWER CROSSMEMBER
6 - U-NUT

Fig. 37 Radiator Alignment Dowels-Typical
Fig. 37 Radiator Alignment Dowels-Typical

1 - ALIGNMENT DOWEL
2 - RADIATOR
3 - AIR CONDITIONING CONDENSER
4 - GROMMET

(12) Fill cooling system with correct coolant. Refer to the Coolant section of this group.

(13) Install pressure cap.

(14) Check and adjust automatic transmission fluid level (if equipped).

(15) Start engine and visually check for leaks.

Radiator-4.0L

WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED.

SERIOUS BURNS FROM THE COOLANT CAN OCCUR.

DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse.

WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES.

WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS.

ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 11). If replacement is necessary, use only an original equipment clamp with matching number or letter.

REMOVAL

(1) Disconnect battery negative cable.

(2) Observe the previous WARNINGS.

(3) Remove radiator pressure cap.

(4) For access to radiator draincock, remove radiator grill mounting screws and remove grill. Refer to Group 23, Body for procedures.

(5) Attach one end of a 24 inch long X 1/4 inch ID hose to the radiator petcock (Fig. 38). Put the other end into a clean container. Open petcock and drain radiator.

(6) Disconnect electric cooling fan electrical connector, if equipped.

Fig. 38 Radiator Petcock-Typical

Fig. 38 Radiator Petcock-Typical

1 - RADIATOR PETCOCK

(7) If equipped, remove two electric cooling fan mounting bolts. Lift cooling fan straight up until alignment tabs at the bottom are clear of slots in bracket at bottom of radiator (Fig. 39).

(8) Remove the two mechanical (non-electrical) fan shroud mounting bolts. Lift shroud straight up until alignment tabs at the bottom are clear of slots in bracket at bottom of radiator (Fig. 39). Place shroud over mechanical fan.

(9) If equipped, disconnect and plug automatic transmission fluid cooler lines. Quick Connect Fitting Release Tool 6935 may be needed. If equipped with remote transmission cooler, remove line to cooler from bracket at bottom of radiator.

Fig. 39 Radiator Removal/Installation-4.0L Engines
Fig. 39 Radiator Removal/Installation-4.0L Engines

1 - (LHD)
2 - (RHD)
3 - VISCOUS FAN SHROUD
4 - ELECTRIC FAN MODULE
5 - ISOLATOR
6 - RADIATOR
7 - LOWER CROSSMEMBER
8 - U-NUT
9 - UPPER CROSSMEMBER

(10) Disconnect radiator upper and lower hoses clamps. Disconnect radiator upper and lower hoses.

(11) Mark the position of the hood latch striker on the radiator crossmember and remove hood latch striker.

(12) Remove two radiator upper crossmember to isolator nuts (Fig. 39).

(13) Remove four radiator upper crossmember bolts and remove upper crossmember.

(14) If equipped with air conditioning, separate radiator from condenser by removing condenser-to-radiator mounting brackets (Fig. 40).

(15) Lift radiator straight up and out of engine compartment taking care not to damage fins.

INSTALLATION

The radiator is supplied with two alignment dowels (Fig. 41). They are located on the bottom tank and fit into rubber grommets in the radiator lower crossmember.

(1) Lower radiator into engine compartment. Position alignment dowels into rubber grommets in radiator lower crossmember (Fig. 41) (2) If equipped with air conditioning, attach condenser to radiator with mounting brackets (Fig. 40).

(3) Install radiator upper crossmember and four mounting bolts.

(4) Install radiator upper crossmember-to-isolator nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If isolator-to-radiator nuts had been removed, tighten them to 5 N·m (47 in. lbs.) torque.

(5) Install hood latch striker. Note previously marked position.

(6) Connect radiator upper and lower hoses.

(7) If equipped, connect automatic transmission fluid cooler lines. Refer to Group 21, Transmissions for procedures. If equipped with remote cooler, attach cooler line to bracket at bottom of radiator.

Fig. 40 Condenser to Radiator Mounting Brackets-4.0L Engine
Fig. 40 Condenser to Radiator Mounting Brackets-4.0L Engine

1 - CONDENSER TO RADIATOR MOUNTING BRACKETS

Fig. 41 Radiator Alignment Dowels-Typical
Fig. 41 Radiator Alignment Dowels-Typical

1 - ALIGNMENT DOWEL
2 - RADIATOR
3 - AIR CONDITIONING CONDENSER
4 - GROMMET

(8) Install electric cooling fan (if equipped). Insert alignment tabs at bottom of fan shroud into slots in bracket at bottom of radiator. Tighten mounting bolts to 3 N·m (31 in. lbs.) torque.

(9) Connect electric cooling fan electrical connector.

(10) Install mechanical cooling fan shroud. Insert alignment tabs at bottom of shroud into slots in bracket at bottom of radiator. Tighten mounting bolts to 3 N·m (31 in. lbs.) torque.

(11) Close radiator draincock.

(12) Install grill.

(13) Connect negative battery cable.

(14) Fill cooling system with correct coolant. Refer to the Coolant section of this group.

(15) Install pressure cap.

(16) Check and adjust automatic transmission fluid level (if equipped).

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