STANDARD PROCEDURE - COOLING SYSTEM DRAINING When servicing the cooling system, it is essential that coolant does not drip on the drive belts or pul- leys. If neccessary, shield the belts with shop towels before working on the cooling system. If coolant con- tacts the belts or pulleys, flush both with clean water. WARNING: DO NOT REMOVE HOSE CLAMPS OR HOSES, CYLINDER BLOCK DRAIN PLUGS, COOL- ANT BOTTLE CAP, OR OPEN THE RADIATOR DRAINCOCK, WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. The radiator draincock that is located at the lower right side of radiator (Fig. 4). The draincock stem is closed in the horizontal position, pointing to 3:00 o'clock. Draining takes place through the cooling module's lower right side insulator. Do Not Use pli- ers to open draincock. CAUTION: Do not pull outward on the draincock flange while opening. Damage to the draincock body and O-ring seal may occur (1) To open the draincock to the minimum drain position, turn the draincock stem countercolockwise to the 12:00 o'clock position. For the maximum drain position, turn draincock stem counterclockwise 180 degrees to the 9:00 o'clock position. (2) Remove coolant pressure bottle cap and open the bleed valve. (3) Remove the cylinder block drain plug(s) located below each exhaust manifold. Most service drains are about 80 percent of capac- ity because not all coolant is drained from system. For capacity specifications, (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS - FLUID CAPACITIES) CAUTION: The cooling system normally operates at 97-124 kPa (14-18 psi) pressure. Exceeding this pressure may damage the radiator or hoses.
STANDARD PROCEDURE - COOLING SYSTEM FILLING 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. CAUTION: Do not use well water, or suspect water supply in cooling system. Use only a 50/50 mixture of the specified ethylene glycol type antifreeze/cool- ant and distilled water. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). (1) Close radiator draincock by turning the stem clockwise to the 3:00 o'clock position. Hand tighten only. (2) Install engine block drain plugs, if removed. COOLING WARNING: WHEN INSTALLING DRAIN HOSE TO AIR BLEED VALVE, ROUTE HOSE AWAY FROM ACCES- SORY DRIVE BELTS, ACCESSORY DRIVE PULLEYS, AND ELECTRIC COOLING FAN MOTORS. (3) Attach one end of a 6.35 mm (0.250 in.) ID clear hose that is approximately 1200 mm (48 in.) long, to the bleed valve. Bleed Valve Location (2.7L): Located on the water outlet connector at the front of engine (Fig. 5). Bleed Valve Location (3.5L): Located on the lower intake manifold, left of center and below the upper intake plenum (Fig. 5). (4) Route hose away from the accessory drive belt, drive pulleys and electric cooling fan. Place the other end of hose into a clean container. The hose will pre- vent coolant from contacting the accessory drive belt when bleeding the system during the refilling opera- tion (Fig. 5). (5) Open the cooling system bleed valve (Fig. 5). (6) Attach Special Tool 8195, Filling Aid Funnel to pressure bottle filler neck (Fig. 6). (7) Use the supplied clip to pinch overflow hose that connects between the two chambers of the cool- ant bottle (Fig. 6). Fig. 5 COOLING SYSTEM BLEEDING LH COOLING 7 - 9 COOLING (Continued)CAUTION: Do not mix coolants. If coolant is used other than specified, a reduction in corrosion pro- tection will occur. (8) Pour a 50/50 mix of Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula and distilled water into the larger section of Filling Aid Funnel (the smaller section of funnel is to allow air to escape). For system capacity, (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS - FLUID CAPACITIES). (9) Slowly fill the cooling system until a steady stream of coolant flows from the hose attached to the bleed valve (Fig. 5). (10) Close the bleed valve and continue filling sys- tem to the top of the Filling Funnel. (11) Remove clip from overflow hose (Fig. 6). (12) Allow the coolant in Filling Funnel to drain into overflow chamber of the pressure bottle. (13) Remove Special Tool 8195, Filling Aid Funnel. Install cap on coolant pressure bottle. (14) Remove hose from bleed valve. (15) Start engine and run until it reaches operating temperature. 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 cool- ant level in the pressure bottle may occur. If the engine cooling system overheats and pushes cool- ant 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. (16) Shut off engine allow it to cool down. This permits coolant to be drawn into the pressure cham- ber. (17) With engine COLD, observe coolant level in pressure chamber. Coolant level should be within MIN and MAX marks. Adjust coolant level as neces- sary. NOTE: The coolant bottle has two chambers. Cool- ant will normally only be in the inboard (smaller) of the two. The outboard chamber is only to recover coolant in the event of an overheat or after a recent service fill. The outboard chamber should normally be empty. If there is coolant in the overflow side of the coolant bottle (after several warm/cold cycles of the engine) and coolant level is within MIN and MAX marks, disconnect the end of the overflow hose at the fill neck and lower it into a clean container. Allow coolant to drain into the container until emp- tied. Reconnect overflow hose to fill neck. -- --Geoff Cell: (313)506-7295 Sterling Heights CERT '04 Grand Cherokee | '05 Town & Country http://www.moparmailinglist.com [Non-text portions of this message have been removed] ------------------------------------ Web: <http://groups.yahoo.com/group/dodge_intrepid> Subscribe: <mailto://[EMAIL PROTECTED]> Unsubscribe: <mailto://[EMAIL PROTECTED]> Moderator: <mailto://[EMAIL PROTECTED]>Yahoo! Groups Links <*> To visit your group on the web, go to: http://groups.yahoo.com/group/dodge_intrepid/ <*> Your email settings: Individual Email | Traditional <*> To change settings online go to: http://groups.yahoo.com/group/dodge_intrepid/join (Yahoo! 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