Jeep XJ. Manual — part 78
COOLANT REPLACEMENT
It is recommended that the cooling system be
drained and flushed at 84,000 kilometers (52,500
miles), or 3 years, whichever occurs first. Then every
two years, or 48,000 kilometers (30,000 miles),
whichever occurs first.
REMOVAL AND INSTALLATION
RADIATOR
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 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
(Fig.
15).
ALWAYS
WEAR
SAFETY
GLASSES WHEN SERVICING CONSTANT TENSION
CLAMPS.
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.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Observe the previous WARNINGS.
(3) Drain cooling system. Refer to Draining Cool-
ing System in this group.
(4) Remove the upper fan shroud-to-upper cross-
member mounting bolts. One of the bolts is mounted
vertically at the bottom of the fan shroud.
(5) Lift the fan shroud up until alignment tabs at
the bottom are clear of slots in bracket at bottom of
radiator. Slip the fan shroud rearward and position it
over the fan blades.
(6) Remove radiator hose clamps and remove radi-
ator hoses.
(7) Mark the position of the hood latch striker on
the radiator crossmember and remove hood latch
striker.
(8) Remove radiator upper crossmember.
(9) If equipped with air conditioning, separate the
radiator from the A/C condenser by removing the
condenser-to-radiator mounting brackets.
(10) Lift radiator straight up and out of engine
compartment taking care not to damage radiator or
A/C condenser fins.
INSTALLATION
The radiator is equipped with two alignment dow-
els (Fig. 17). They are located on the bottom of the
Fig. 15 Hose Clamp Tool
1 – HOSE CLAMP TOOL 6094
2 – HOSE CLAMP
Fig. 16 Clamp Number/Letter Location
1 – TYPICAL CONSTANT TENSION HOSE CLAMP
2 – CLAMP NUMBER/LETTER LOCATION
3 – TYPICAL HOSE
7 - 20
COOLING SYSTEM
XJ
SERVICE PROCEDURES (Continued)
2000 JEEP CHEROKEE
plastic side tanks and fit into rubber grommets
located in the front lower crossmember.
(1) Carefully lower the radiator into engine com-
partment. Position the alignment dowels on the bot-
tom of radiator into the rubber grommets in front
lower crossmember (Fig. 17).
(2) If equipped with air conditioning, attach con-
denser to radiator with mounting brackets.
(3) Install radiator upper crossmember.
(4) Install hood latch striker.
(5) Connect radiator upper and lower hoses.
(6) Insert alignment tabs at bottom of fan shroud
into slots in bracket at bottom of radiator. Install and
tighten fan shroud bolts to 3 N·m (31 in. lbs.) torque.
(7) Connect negative battery cable.
(8) Fill cooling system with correct coolant. Refer
to Refilling Cooling System in this group.
(9) Start and warm the engine. Check for coolant
leaks.
FAN BLADE REMOVAL
FAN BLADE REMOVAL
Accessory drive belt removal is not necessary for
fan blade or viscous fan drive removal.
(1) Disconnect negative battery cable from battery.
(2) The thermal viscous fan drive/fan blade assem-
bly is attached (threaded) to the fan pulley shaft
(Fig. 18). Remove fan blade/viscous fan drive assem-
bly from fan pulley by turning mounting nut counter-
clockwise as viewed from front. Threads on viscous
fan drive are RIGHT HAND. Snap-On
t 36 MM Fan
Wrenches (number SP346) can be used to turn the
mounting nut and to hold the fan pulley from rotat-
ing.
(3) Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
(4) Do not unbolt fan blade assembly from viscous
fan drive at this time.
(5) Remove the fan shroud mounting bolts.
(6) Remove the fan shroud and fan blade/viscous
fan drive assembly as a complete unit from vehicle.
(7) After removing fan blade/viscous fan drive
assembly, do not place viscous fan drive in horizon-
tal position. If stored horizontally, silicone fluid in
the viscous fan drive could drain into its bearing
assembly and contaminate lubricant.
Fig. 17 Radiator Alignment Dowels—Typical
1 – ALIGNMENT DOWEL
2 – RADIATOR
3 – AIR CONDITIONING CONDENSER
4 – GROMMET
Fig. 18 Thermal Viscous Fan Drive and Blade
Assembly
1 – FAN PULLEY
2 – FAN DRIVE-TO-FAN BLADE BOLTS (4)
3 – MOUNTING NUT
4 – THERMAL VISCOUS FAN DRIVE
5 – FAN BLADES
6 – FAN PULLEY SHAFT
7 – WATER PUMP
XJ
COOLING SYSTEM
7 - 21
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
CAUTION: Do not attempt to remove the fan pulley
bolts. The fan pulley is under tension from the drive
belt.
(7) Remove four bolts securing fan blade assembly
to viscous fan drive (Fig. 18).
FAN BLADE INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 18) to 23 N·m (200 in. lbs.) torque.
(2) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(3) Install and tighten fan shroud bolts to 3 N·m
(31 in. lbs.) torque.
(4) Install fan blade/viscous fan drive assembly to
fan pulley shaft (Fig. 18).
(5) Connect the negative battery cable.
VISCOUS FAN DRIVE
Refer to the FAN BLADE removal and installation
procedure for replacement of the viscous fan drive.
The thermal viscous fan drive (Fig. 19) is a sili-
cone-fluid-filled coupling. It connects the fan blade
assembly to the fan pulley. The coupling allows the
fan to be driven in a normal manner. This is done at
low engine speeds while limiting the top speed of the
fan to a predetermined maximum level at higher
engine speeds. A bimetallic spring coil is located on
the front face. This spring coil reacts to the temper-
ature of the radiator discharge air. It engages the
viscous fan drive for higher fan speed if the air tem-
perature from the radiator rises above a certain
point. Until additional engine cooling is necessary,
the fan will remain at a reduced rpm regardless of
engine speed.
The viscous fan drive will only engage when suffi-
cient heat is present. This is when the air flowing
through the radiator core causes a reaction from the
bimetallic coil. It then increases fan speed to provide
the necessary additional engine cooling.
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
• The underhood temperature is above the engage-
ment point for the viscous drive coupling. This may
occur when ambient (outside air temperature) is very
high.
• Engine loads and temperatures are high such as
when towing a trailer.
• Cool silicone fluid within the fan drive unit is
being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
THERMOSTAT
REMOVAL
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 the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing. Refer to
Draining Cooling System for procedures.
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
(Fig.
15).
ALWAYS
WEAR
SAFETY
GLASSES WHEN SERVICING CONSTANT TENSION
CLAMPS.
Fig. 19 Viscous Fan Drive
1 – MOUNTING NUT TO FAN PULLEY SHAFT
2 – THERMOSTATIC SPRING
3 – VISCOUS FAN DRIVE
7 - 22
COOLING SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
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)
2000 JEEP CHEROKEE
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