Jeep Cherokee (XJ): Transmission oil coolers. Coolant reserve tank. Water pump

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Cooling system > Removal and installation > Transmission oil coolers. Coolant reserve tank. Water pump

Transmission oil coolers

WATER-TO-OIL COOLER

The internal transmission oil cooler located within the radiator is not serviceable. If it requires service, the radiator must be replaced.

Once the repaired or replacement radiator has been installed, fill the cooling system and inspect for leaks.

Refer to the Refilling Cooling System and Testing Cooling System For Leaks sections in this group. If the transmission operates properly after repairing the leak, drain the transmission and remove the transmission oil pan. Inspect for sludge and/or rust. Inspect for a dirty or plugged inlet filter. If none of these conditions are found, the transmission and torque convertor may not require reconditioning. Refer to Group 21 for automatic transmission servicing.

AIR-TO-OIL COOLER

REMOVAL

(1) Remove the grill mounting screws and remove the grill. Refer to Group 23, Body for procedures.

(2) Place a drain pan below the transmission oil cooler.

(3) Remove the two constant tension clamps at oil cooler inlet and outlet tubes.

(4) Remove the two oil cooler mounting bolts (Fig.

22).

(5) Remove the oil cooler from vehicle.

INSTALLATION

(1) Position and secure oil cooler to vehicle.

Tighten mounting bolts to 8 N·m (72 in. lbs.) torque.

(2) Secure inlet and outlet tubes with constant tension clamps.

Install the grill.

(3) Start engine and check transmission fluid level.

Add fluid if necessary.

Coolant reserve tank

REMOVAL

(1) Remove the tube clamp at the tank and remove tube.

Fig. 22 Auxiliary Air-To-Oil Cooler
Fig. 22 Auxiliary Air-To-Oil Cooler

1 - AIR CONDITIONING CONDENSER
2 - HOSE CLAMPS (2)
3 - AUXILIARY AUTOMATIC TRANSMISSION OIL COOLER
4 - MOUNTING BOLT
5 - MOUNTING BOLT

(2) Remove the tank mounting bolts and remove tank (Fig. 23) (Fig. 24).

Fig. 23 Reserve/Overflow Tank-Except Right Hand Drive
Fig. 23 Reserve/Overflow Tank-Except Right Hand Drive

1 - COOLANT RESERVE/OVERFLOW TANK
2 - CLAMP
3 - MOUNTING BOLTS
4 - TUBE TO RADIATOR

Fig. 24 Reserve/Overflow Tank-With Right Hand Drive
Fig. 24 Reserve/Overflow Tank-With Right Hand Drive

1 - CLAMP
2 - COOLANT RESERVE/OVERFLOW TANK
3 - MOUNTING BOLTS
4 - LOWER BRACKET
5 - TUBE TO RADIATOR

INSTALLATION

(1) Position tank and tighten to 2 N·m (17 in. lbs.) torque.

(2) Position tube and secure clamp.

Water pump

CAUTION: If the water pump is replaced because of mechanical damage, the fan blades and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration.

The water pump can be removed without discharging the air conditioning system (if equipped).

CAUTION: All engines have a reverse (counterclockwise) rotating water pump. The letter R is stamped into the back of the water pump impeller (Fig. 25) to identify. Engines from previous model years, depending upon application, may be equipped with a forward (clockwise) rotating water pump. Installation of the wrong water pump will cause engine over heating.

Fig. 25 Reverse Rotating Water Pump-Typical
Fig. 25 Reverse Rotating Water Pump-Typical

1 - R STAMPED INTO IMPELLER

The water pump impeller is pressed on the rear of the pump shaft and bearing assembly. The water pump is serviced only as a complete assembly.

WARNING: DO NOT REMOVE THE BLOCK DRAIN PLUG(S) OR LOOSEN RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE.

SERIOUS BURNS FROM COOLANT CAN OCCUR.

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

REMOVAL-2.5L ENGINE (LHD/RHD)

(1) Disconnect battery negative cable.

(2) Drain cooling system. Refer to Cooling System- Draining and Filling in this group.

(3) Remove upper radiator hose.

(4) Loosen (but do not remove at this time) the four fan hub-to-water pump pulley mounting nuts (Fig. 26).

(5) Remove accessory drive belt. (Refer to Accessory Drive Belt, Removal and Installation in this group) (6) Disconnect electric cooling fan connector (if equipped).

(7) Unbolt fan shroud.

(8) Remove the four fan hub-to-water pump pulley nuts and remove fan and shroud together.

CAUTION: After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant.

(9) Remove power steering pump and bracket (Fig.

27), refer to Group 19 Steering for correct procedure.

(10) Remove lower radiator hose from water pump.

Remove heater hose from water pump pipe.

(11) Remove the four pump mounting bolts (Fig.

28) and remove pump from vehicle. Discard old gasket.

Note that one of the four bolts is longer than the other bolts.

(12) If pump is to be replaced, the heater hose fitting must be removed. Note position of fitting before removal.


Fig. 26 Fan Mounting Nuts

1 - THERMAL VISCOUS FAN DRIVE
2 - (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 - (4) FAN HUB-TO-PUMP PULLEY STUDS
4 - WATER PUMP
5 - WATER PUMP PULLEY
6 - FAN BLADE
7 - (4) FAN HUB-TO-PUMP PULLEY NUTS

INSTALLATION-2.5L ENGINE (LHD/RHD)

(1) If pump is being replaced, install the heater hose pipe to the pump. Use a sealant on the fitting such as Mopart Thread Sealant With Teflon. Refer to the directions on the package.

(2) Clean the gasket mating surfaces. If the original pump is used, remove any deposits or other foreign material. Inspect the cylinder block and water pump mating surfaces for erosion or damage from cavitation.

Fig. 27 Power Steering Pump Attachment-2.5L
Fig. 27 Power Steering Pump Attachment-2.5L

1 - INTAKE MANIFOLD
2 - PUMP ASSEMBLY 2.5L
3 - PUMP BRACKET

Fig. 28 Water Pump Remove/Install-Typical
Fig. 28 Water Pump Remove/Install-Typical

1 - HEATER HOSE FITTING
2 - UPPER VENT HOLE
3 - PUMP GASKET
4 - WATER PUMP
5 - LOWER VENT HOLE
6 - LONG BOLT
7 - BOLTS (3) SHORT

(3) Install the gasket and water pump. The silicone bead on the gasket should be facing the water pump. Also, the gasket is installed dry. Tighten mounting bolts to 23 N·m (17 ft. lbs.) torque. Rotate the shaft by hand to be sure it turns freely.

(4) Connect the radiator and heater hoses to the water pump.

(5) Install power steering pump and bracket. Refer to Group 19, Steering.

(6) Position water pump pulley to water pump hub.

(7) Install shroud and fan together and install four nuts to water pump hub studs. Tighten nuts to 27 N·m (20 ft. lbs.) torque.

(8) Install and tighten upper fan shroud nuts to 4 N·m (31 in. lbs.).

(9) Connect electric fan connector (if equipped).

CAUTION: When installing the accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to the Belt Removal and Installation in this group for appropriate belt routing.

You may also refer to the Belt Routing Label in the vehicle engine compartment.

(10) Install and tension accessory drive belt, refer to Accessory Drive Belt removal and installation in this group.

(11) Install upper radiator hose.

(12) Fill cooling system with coolant and check for leaks. Refer to Refilling Cooling System in this group.

(13) Connect battery negative cable.

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

REMOVAL-4.0L ENGINE (LHD/RHD)

(1) Disconnect battery negative cable.

(2) Drain the cooling system. (Refer to Cooling System-Draining and Filling in this group.) (3) Disconnect electric cooling fan connector.

(4) Remove electric cooling fan/shroud assembly (if equipped).

(5) Remove viscous fan shroud bolts (2).

(6) Loosen (but do not remove at this time) the four water pump pulley-to-water pump hub mounting bolts (Fig. 29) and the four viscous fan to idler pulley nuts.

NOTE: The accessory drive belt must be removed prior to removing the fan (if installed at pump) or fan pulley.

(7) Remove accessory drive belt (refer to Accessory Drive Belt, Removal and Installation in this group)

Fig. 29 Water Pump Pulley Bolts
Fig. 29 Water Pump Pulley Bolts

1 - WATER PUMP HUB
2 - BOLTS (4)
3 - PUMP PULLEY

(8) Remove the four viscous fan to idler pulley nuts and remove the fan and shroud together.

CAUTION: After removing fan blade/viscous fan drive assembly, do not place thermal viscous fan drive in horizontal position. If stored horizontally, silicone fluid in viscous fan drive could drain into its bearing assembly and contaminate lubricant.

(9) Remove the four water pump pulley bolts and remove the pulley.

(10) Remove power steering pump and bracket (Fig. 30), refer to Group 19 Steering.

(11) Remove lower radiator hose from water pump.

Remove heater hose from water pump fitting.

(12) Remove the four pump mounting bolts (Fig.

31) and remove pump from vehicle. Discard old gasket.

Note that one of the four bolts is longer than the other bolts.

(13) If pump is to be replaced, the heater hose fitting must be removed. Note position of fitting before removal.

INSTALLATION-4.0L ENGINE (LHD/RHD)

(1) If pump is being replaced, install the heater hose fitting to the pump. Use a sealant on the fitting such as Mopart Thread Sealant With Teflon. Refer to the directions on the package.

(2) Clean the gasket mating surfaces. If the original pump is used, remove any deposits or other foreign material. Inspect the cylinder block and water pump mating surfaces for erosion or damage from cavitation.

(3) Install the gasket and water pump. The silicone bead on the gasket should be facing the water pump. Also, the gasket is installed dry. Tighten mounting bolts to 23 N·m (17 ft. lbs.) torque. Rotate the shaft by hand to be sure it turns freely

Fig. 30 Power Steering Pump Attachment-4.0L
Fig. 30 Power Steering Pump Attachment-4.0L

1 - PUMP ASSEMBLY
2 - PUMP BRACKET

(4) Connect the radiator and heater hoses to the water pump.

(5) Position water pump pulley to water pump hub.

(6) Install four pump pulley bolts. Tighten bolts (or nuts) to 27 N·m (20 ft. lbs.) torque.

(7) Install power steering pump. Refer to Group 19, Steering for proper procedure and torque values.

(8) Install the viscous fan and shroud together.

Install the four fan to idler pulley nuts and tighten to 27 N·m (20 ft. lbs.).

CAUTION: When installing the accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to the Belt Removal and Installation in this group for appropriate belt routing.

You may also refer to the Belt Routing Label in the vehicle engine compartment.

(9) Install and tighten viscous fan shroud bolts to 4 N·m (31 in. lbs.).

(10) Install and tension the accessory drive belt, refer to Accessory Drive Belt removal and installation in this group.

(11) Install the electric cooling fan/shroud assy.

(12) Install and tighten electric fan shroud bolts to 4 N·m (31 in. lbs.). Connect fan connector.

Fig. 31 Water Pump Remove/Install-Typical
Fig. 31 Water Pump Remove/Install-Typical

1 - HEATER HOSE FITTING
2 - UPPER VENT HOLE
3 - PUMP GASKET
4 - WATER PUMP
5 - LOWER VENT HOLE
6 - LONG BOLT
7 - BOLTS (3) SHORT

(13) Fill cooling system with coolant and check for leaks. Refer to Refilling Cooling System in this group.

(14) Connect battery negative cable.

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

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