Coolant Line/Hose: Service and Repair
WATER PUMP INLET TUBEREMOVAL-WATER PUMP BYPASS HOSE WITH AIR CONDITIONING
If equipped with A/C, the generator and A/C compressor along with their common mounting bracket must be partially removed. Removing the generator or A/C compressor from their mounting bracket is not necessary. Also discharging the A/C system is not necessary. Do not remove any refrigerant lines from A/C compressor.
WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH THE ENGINE OFF. REFER TO REFRIGERANT WARNINGS IN HEATING AND AIR CONDITIONING.
1. Disconnect negative battery cable from battery.
2. Partially drain cooling system.
2. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
3. Remove upper radiator hose clamp at radiator. A special clamp tool must be used to remove the constant tension clamps. Remove hose at radiator.
4. Disconnect throttle cable from clip at radiator fan shroud.
5. Unplug wiring harness from A/C compressor.
6. Remove the air cleaner assembly.
7. Remove accessory drive belt.
8. 3.9L V6 or 5.2/5.9L V8 LDC Gas: The drive belt idler pulley must be removed to gain access to one of the A/C compressor/generator bracket mounting bolts. Remove the idler pulley bolt and remove idler pulley.
9. 5.9L HDC Gas: The automatic belt tensioner/pulley assembly must be removed to gain access to one of the A/C compressor/generator bracket mounting bolts. Remove the tensioner mounting bolt and remove tensioner.
10. Remove the engine oil dipstick tube mounting bolt at the side of the A/C generator mounting bracket.
11. Disconnect throttle body control cables.
12. Remove heater hose coolant return tube mounting bolt and remove tube from engine. Discard the old tube O-ring.
13. Remove bracket to intake manifold bolts (number 1 and 2).
14. Remove remaining bracket-to-engine bolts.
15. Lift and position generator and A/C compressor (along with their common mounting bracket) to gain access to bypass hose. A block of wood may be used to hold assembly in position.
16. Loosen and position both hose clamps to the center of bypass hose. A special clamp tool must be used to remove the constant tension clamps. Remove hose from vehicle.
REMOVAL-WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING
A water pump bypass hose is used between the intake manifold and water pump on all gas powered engines. To test for leaks, refer to Test in Cooling System for Leaks.
1. Partially drain cooling system. Do not waste reusable coolant. If the solution is clean, drain the 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). SNAP-ON CLAMP TOOL (NUMBER HPC20) 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. If replacement is necessary, use only an original equipment clamp with a matching number or letter.
2. Loosen both bypass hose clamps and position to the center of hose.
3. Remove hose from vehicle.
INSTALLATION-WATER PUMP BYPASS HOSE WITH AIR CONDITIONING
1. Position bypass hose clamps to the center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Install generator A/C mounting bracket assembly to engine. Tighten bolt number 1 to 41 Nm (30 ft. lbs.) torque. Tighten bolt number 2 to 28 Nm (30 ft. lbs.) torque. Tighten bracket mounting bolts to 40 Nm (30 ft. lbs.) torque.
5. Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
6. Install coolant return tube and its mounting bolt to engine.
7. Connect throttle body control cables.
8. Install oil dipstick mounting bolt.
9. 3.9L V6 or 5.2/5.9L V8 LDC Gas Engines: Install idler pulley. Tighten bolt to 41 Nm (30 ft. lbs.) torque.
10. 5.9L HDC Gas: Install automatic belt tensioner assembly to mounting bracket. A dowel pin is located on back of tensioner. Align this to dowel hole in tensioner mounting bracket. Tighten bolt to 41 Nm (30 ft. lbs.) torque.
11. Install drive belt.
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. The correct belt with the correct length must be used.
12. Install air cleaner assembly.
13. Install upper radiator hose to radiator.
14. Connect throttle cable to clip at radiator fan shroud.
15. Connect wiring harness to A/C compressor.
16. Fill cooling system.
17. Start and warm the engine. Check for leaks.
INSTALLATION-WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING
1. Position bypass hose clamps to the center of hose.
2. Install bypass hose to engine.
3. Secure both hose clamps.
4. Fill cooling system.
5. Start and warm the engine. Check for leaks.