Jeep 200 Cherokee, Service Manual

Page: 278 / 2119

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 tempera-
ture 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 PRES-
SURIZED. 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 SERVIC-
ING 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 radia-
tor 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 con-
nector, if equipped.
(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 sup-
port 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-ra-
diator 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 cross-
member.
Fig. 34 Radiator Petcock—Typical
1 – RADIATOR PETCOCK
XJ
COOLING SYSTEM 7 - 29
REMOVAL AND INSTALLATION (Continued)