Jeep 200 Cherokee, Service Manual

Page: 312 / 2119

CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 16). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(2) Remove the upper radiator hose at the thermo-
stat housing.
(3) Remove the four thermostat housing bolts (Fig.
20)
(4) Remove the thermostat housing from the water
manifold.
(5) Remove the thermostat and rubber seal from
the water manifold.
(6) Thoroughly clean the rubber seal mating sur-
faces.
INSTALLATION
(1) Install a new rubber seal around the outer lip
of the thermostat (a notch is provided in the rubber
seal). Do not apply any adhesive to this seal.
(2) Install the replacement thermostat and rubber
seal as one assembly into the water manifold adapter
(the pointed end of the thermostat should be facing
towards the front of engine (Fig. 20). Observe the
recess groove in the water manifold adapter. Be sure
the thermostat vent is in the 12 o’clock position (Fig.
20).
(3) Position the thermostat housing and four bolts
to the water manifold.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
groove, may result in a cracked housing.
(4) Tighten the four housing bolts to 11 N·m (98
in. lbs.) torque.
(5) Install radiator hose to thermostat housing.
(6) Be sure that the radiator drain is tightly
closed. Fill the cooling system to the correct level
with the required coolant mixture. Refer to Refilling
Cooling System in this group for procedures.
(7) Start and warm the engine. Check thermostat
and hose for leaks.
DRIVE BELT
CAUTION: The drive belt on the 2.5L diesel engine
is equipped with a spring loaded automatic belt ten-
sioner. After belt installation, do not attempt to
check belt tension with a belt tension gauge.
AUTOMATIC BELT TENSIONER
WATER PUMP
REMOVAL
The water pump can be removed without discharg-
ing the air conditioning system (if equipped).
The water pump is serviced by replacing the pump
and its impeller only. The water pump adapter (Fig.
22) does not have to be removed. The pump impeller
is pressed on the rear of the pump shaft and bearing
assembly. The pump is serviced only as a complete
assembly with the impeller, housing, hub and bear-
ing.
A rubber o-ring seal (instead of a gasket) is used as
a seal between the water pump and the water pump
adapter.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN-PLUG, THE COOLANT TANK CAP,
THE RADIATOR FILL VENT VALVE, OR LOOSEN
THE RADIATOR DRAINCOCK WITH THE SYSTEM
HOT AND PRESSURIZED. SERIOUS BURNS FROM
THE COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution
is clean, drain coolant into a clean container for
reuse.
(1) Disconnect the negative battery cable.
Fig. 20 Thermostat Removal/Installation
1 – THERMOSTAT RECESS GROOVE
2 – WATER MANIFOLD ADAPTER
3 – THERMOSTAT
4 – THERMOSTAT HOUSING
5 – HOUSING BOLTS (4)
6 – WASHER
7 – RUBBER SEAL
8 – VENT
XJ
COOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)