Jeep XJ. Manual — part 70
(13) Fill cooling system with coolant and check for
leaks. Refer to Refilling Cooling System in this
group.
(14) Connect battery negative cable.
(15) Start and warm the engine. Check for leaks.
THERMOSTAT
REMOVAL
WARNING: DO
NOT
LOOSEN
THE
RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing.
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.
(2) Remove radiator upper hose and heater hose at
thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 32).
Discard old gasket.
(5) Clean the gasket mating surfaces.
INSTALLATION
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl-
inder head (Fig. 33).
(b) Position thermostat into this groove with
arrow and air bleed hole on outer flange pointing
up.
(2) Install replacement gasket and thermostat
housing.
Fig. 32 Thermostat Removal/Installation
1 – LONG BOLT
2 – GASKET
3 – THERMOSTAT
4 – THERMOSTAT HOUSING
5 – SHORT BOLT
Fig. 33 Thermostat Recess
1 – GROOVE
7 - 28
COOLING SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
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)
(1) Lower radiator into engine compartment. Posi-
tion alignment dowels into rubber grommets in radi-
ator lower crossmember (Fig. 41).
(2) If equipped with air conditioning, attach con-
denser to radiator with mounting brackets (Fig. 35).
(3) Install radiator upper crossmember and four
mounting bolts.
(4) Install radiator upper crossmember-to-isolator
nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If
isolator-to-radiator nuts had been removed, tighten
them to 5 N·m (47 in. lbs.) torque.
(5) Connect radiator upper and lower hoses.
(6) If equipped, connect automatic transmission
fluid cooler lines. If equipped with remote cooler,
attach cooler line to bracket at bottom of radiator.
(7) Install electric fan (if equipped) and shroud
assembly.. Insert alignment tabs at bottom of fan
shroud into slots in bracket at bottom of radiator.
Tighten mounting bolts to 3 N·m (31 in. lbs.) torque.
(8) Connect electric cooling fan electrical connector.
(9) Install power steering reservoir to fan shroud.
(10) Install grill.
(11) Connect battery negative cable.
Fig. 35 Condenser-to-Radiator Mounting Brackets
1 – CONDENSER TO RADIATOR MOUNTING BRACKETS
Fig. 36 Radiator Removal/Installation—2.5L Engines
1 – ELECTRIC FAN/SHROUD ASSEMBLY
2 – UPPER CROSSMEMBER
3 – ISOLATOR
4 – RADIATOR
5 – LOWER CROSSMEMBER
6 – U-NUT
7 - 30
COOLING SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(12) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(13) Install pressure cap.
(14) Check and adjust automatic transmission
fluid level (if equipped).
(15) Start engine and visually check for leaks.
RADIATOR—4.0L
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. 38). Put the other
end into a clean container. Open petcock and drain
radiator.
(6) Disconnect electric cooling fan electrical con-
nector, if equipped.
(7) If equipped, remove two electric cooling fan
mounting bolts. Lift cooling fan straight up until
alignment tabs at the bottom are clear of slots in
bracket at bottom of radiator (Fig. 39).
(8) Remove the two mechanical (non-electrical) fan
shroud mounting bolts. Lift shroud straight up until
alignment tabs at the bottom are clear of slots in
bracket at bottom of radiator (Fig. 39). Place shroud
over mechanical fan.
(9) 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.
Fig. 37 Radiator Alignment Dowels—Typical
1 – ALIGNMENT DOWEL
2 – RADIATOR
3 – AIR CONDITIONING CONDENSER
4 – GROMMET
Fig. 38 Radiator Petcock—Typical
1 – RADIATOR PETCOCK
XJ
COOLING SYSTEM
7 - 31
REMOVAL AND INSTALLATION (Continued)
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