Cooling System Filling
COOLING SYSTEM FILLING
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. In order to maintain the required protection for these components and cooling system performance, only use the appropriate fluid when servicing the vehicle. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37� C (-35� F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.
WARNING: Make sure engine cooling system is cool before removing pressure cap or any hose. severe personal injury may result from escaping hot coolant. The cooling system is pressurized when hot.
NOTE: Cooling system fill procedure is critical to overall cooling system performance.
1. Close radiator draincock. Hand tighten only.
2. Install engine block drain plugs, if removed. Coat the threads with Mopar(R) Thread Sealant with Teflon.
WARNING: When installing drain hose to air bleed valve, route hose away from accessory drive belts, accessory drive pulleys, and electric cooling fan motors.
NOTE: It may be necessary to install a bleed fitting on the 5.7L engine.
3. Attach a 1.5 - 2 m (4 - 6 ft.) long 6.35 mm (1/4 inch.) ID clear hose to bleeder fitting
- Bleed Valve Location (2.7L): Located on the water outlet connector at the front of engine.
- Bleed Valve Location (3.5L): Located on the lower intake manifold, left of center and below the upper intake plenum.
- Plug Location (5.7L/6.1L): Located on the front of the water outlet housing at the front of engine.
4. Route hose (2) away from the accessory drive belt, drive pulleys and electric cooling fan. Place the other end of hose (2) into a clean container. The hose will prevent coolant from contacting the accessory drive belt when bleeding the system during the refilling operation.
NOTE: It is imperative that the cooling system air bleed valve be opened before any coolant is added to the cooling system. Failure to open the bleed valve first will result in an incomplete fill of the system.
5. 5.7L/6.1L ENGINE - Install a threaded and barbed fitting (1/4 - 18 npt) into water pump housing.
6. Attach Tool 8195, Filling Aid Funnel to pressure bottle filler neck.
7. Using hose pinch-off pliers, pinch overflow hose (3) that connects between the two chambers of the coolant bottle (2).
8. Open bleed fitting.
CAUTION: Do not mix coolants. If coolant is used other than specified, a reduction in corrosion protection will occur.
9. Pour the antifreeze mixture.
10. Slowly fill the cooling system until a steady stream of coolant flows from the hose attached to the bleed valve.
11. Close the bleed valve and continue filling system to the top of the Tool 8195, Filling Aid Funnel.
12. Remove pinch-off pliers from overflow hose.
13. Allow the coolant in Filling Funnel to drain into overflow chamber of the pressure bottle.
14. Remove Tool 8195, Filling Aid Funnel. Install cap on coolant pressure bottle.
15. Remove hose from bleed valve.
16. 5.7L/6.1L ENGINE - Install fitting into thermostat housing. Coat the threads with Mopar(R) Thread Sealant with Teflon.
17. Start engine and run at 1500 - 2000 RPM for 30 minutes.
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 coolant level in the pressure bottle may occur. If the engine cooling system overheats and pushes coolant 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.
18. Shut off engine allow it to cool down for 30 minutes. This permits coolant to be drawn into the pressure chamber.
19. With engine COLD, observe coolant level in pressure chamber. Coolant level should be within MIN and MAX marks. Adjust coolant level as necessary.
NOTE: The coolant bottle has two chambers. Coolant will normally only be in the inboard of the two. The outboard chamber is only to recover coolant in the event of an overheat or after a recent service fill.