Jeep XJ. Manual — part 71
(10) Disconnect radiator upper and lower hoses
clamps. Disconnect radiator upper and lower hoses.
(11) Mark the position of the hood latch striker on
the radiator crossmember and remove hood latch
striker.
(12) Remove two radiator upper crossmember to
isolator nuts (Fig. 39).
(13) Remove four radiator upper crossmember
bolts and remove upper crossmember.
(14) If equipped with air conditioning, separate
radiator from condenser by removing condenser-to-ra-
diator mounting brackets (Fig. 40).
(15) Lift radiator straight up and out of engine
compartment taking care not to damage fins.
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.
(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. 40).
(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) Install hood latch striker. Note previously
marked position.
(6) Connect radiator upper and lower hoses.
(7) If equipped, connect automatic transmission
fluid cooler lines. Refer to Group 21, Transmissions
for procedures. If equipped with remote cooler, attach
cooler line to bracket at bottom of radiator.
Fig. 39 Radiator Removal/Installation—4.0L Engines
1 – (LHD)
2 – (RHD)
3 – VISCOUS FAN SHROUD
4 – ELECTRIC FAN MODULE
5 – ISOLATOR
6 – RADIATOR
7 – LOWER CROSSMEMBER
8 – U-NUT
9 – UPPER CROSSMEMBER
7 - 32
COOLING SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(8) Install electric cooling fan (if equipped). 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.
(9) Connect electric cooling fan electrical connector.
(10) Install mechanical cooling fan shroud. Insert
alignment tabs at bottom of shroud into slots in
bracket at bottom of radiator. Tighten mounting bolts
to 3 N·m (31 in. lbs.) torque.
(11) Close radiator draincock.
(12) Install grill.
(13) Connect negative battery cable.
(14) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(15) Install pressure cap.
(16) Check and adjust automatic transmission
fluid level (if equipped).
ELECTRIC COOLING FAN—2.5L
The electric fan module is only to be serviced as an
assembly.
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect CRS hose from radiator filler neck
and pull through (remove) the shroud retaining
loops.
(3) Detach
power
steering
reservoir
from
fan
shroud and lay aside.
(4) Remove the four viscous fan/drive assembly
mounting nuts from the water pump studs and
remove viscous fan assembly.
(5) Disconnect cooling fan electrical connector.
(6) Remove the four upper fan shroud to radiator
crossmember mounting screws (Fig. 42).
(7) Lift fan and shroud assy. from vehicle
(8) Detach fan harness from shroud.
(9) Remove four fan module to shroud phillips
head screws (Fig. 43) and remove module from
shroud.
INSTALLATION
(1) Position fan module in shroud so that the har-
ness exits the motor at the 12 o’clock postion (Fig.
43).
(2) Install and tighten fan module to shroud
screws to 3 N·m (31 in. lbs.).
(3) Route fan harness through the shroud and
attach to shroud at correct position.
(4) Lower fan and shroud assembly into place,
making sure the shroud alignment tabs rest in their
corresponding lower radiator slots.
(5) Install upper fan shroud screws and tighten to
3 N·m (31 in. lbs.).
Fig. 40 Condenser to Radiator Mounting Brackets—
4.0L Engine
1 – CONDENSER TO RADIATOR MOUNTING BRACKETS
Fig. 41 Radiator Alignment Dowels—Typical
1 – ALIGNMENT DOWEL
2 – RADIATOR
3 – AIR CONDITIONING CONDENSER
4 – GROMMET
XJ
COOLING SYSTEM
7 - 33
REMOVAL AND INSTALLATION (Continued)
(6) Connect fan electrical connector.
(7) Install power steering reservoir to shoud.
(8) Install viscous fan drive assy. to water pump
hub and tighten nuts to 27 N·m (20 ft. lbs.)
(9) Connect battery negative cable.
ELECTRIC COOLING FAN—4.0L
REMOVAL
The auxiliary cooling fan is attached to the radia-
tor upper crossmember behind the radiator.
(1) Remove the two fan mounting bolts from radi-
ator upper crossmember (Fig. 44).
(2) Disconnect the electric fan connector.
(3) Lift fan straight up and out of vehicle.
INSTALLATION
(1) Align lower retaining tabs of fan shroud with
slots in bracket at bottom of radiator. Push fan down
into position.
(2) Tighten the mounting bolts to 4 N·m (31 in.
lbs.) torque.
Fig. 42 Fan Shroud Removal/Installation
1 – ELECTRIC FAN/SHROUD ASSEMBLY
2 – UPPER CROSSMEMBER
3 – ISOLATOR
4 – RADIATOR
5 – LOWER CROSSMEMBER
6 – U-NUT
Fig. 43 Fan Module Orientation and Mounting
1 – FAN MOTOR HARNESS AT 12 O’CLOCK POSITION
2 – MOUNTING SCREWS (4)
3 – FAN CONNECTOR
7 - 34
COOLING SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(3) Connect auxiliary cooling fan electrical connec-
tor.
BLOCK HEATER
REMOVAL
Refer to correct illustration (Fig. 45) (Fig. 46) when
servicing block heater.
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.
(1) Drain coolant from radiator and engine cylin-
der block.
(2) Unplug power cord from block heater.
(3) Loosen screw in center of block heater (Fig. 45)
(Fig. 46).
(4) Remove block heater from cylinder block.
INSTALLATION
(1) Thoroughly clean the engine core hole and the
block heater seat.
(2) Insert block heater assembly into core hole
with element loop pointing Up.
(3) Seat block heater flush against block face.
Tighten mounting screw to 3.6 N·m (32 in. lbs.)
torque.
(4) Fill cooling system with coolant. Pressurize
system and inspect for leaks.
(5) Plug power cord into block heater. Route cord
away from moving parts, linkages and exhaust sys-
tem components. Secure cord in place with tie-straps.
ENGINE ACCESSORY DRIVE BELTS
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. There are different types of adjustment
gauges for checking either a serpentine or a V-type
belt. Refer to the instructions supplied with the
Fig. 44 Auxiliary Cooling Fan—Remove/Install—
Typical
1 – ELECTRIC COOLING FAN
2 – MOUNTING BOLT
3 – ELECTRIC COOLING FAN CONNECTOR
4 – MOUNTING BOLT
Fig. 45 Heater and Cord— 2.5L 4-Cylinder Engine
1 – POWER CORD LOCATION
2 – BLOCK HEATER
Fig. 46 Heater and Cord—4.0L 6-Cylinder Engine
1 – POWER CORD LOCATION
2 – BLOCK HEATER
XJ
COOLING SYSTEM
7 - 35
REMOVAL AND INSTALLATION (Continued)
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