Jeep Wrangler TJ. Manual — part 268
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction.
(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
RADIATOR
DESCRIPTION
CAUTION: Plastic tanks, while stronger than brass,
are
subject
to
damage
by
impact,
such
as
wrenches, mishandling, etc.
A heavy duty down-flow aluminum/plastic radiator
is used (Fig. 18). The radiator consists of an alumi-
num core and plastic end tanks, which are fastened
to the core with clinch tabs and sealed with a high
temperature rubber gasket. On automatic transmis-
sion equipped vehicles, the lower tank contains a
concentric-tube transmission oil cooler.
If the plastic tank has been damaged, individual
parts are not available, and the radiator must be
replaced.
OPERATION
As air passes through the radiator core, the heat
within the coolant is dissipated into the ambient air.
DIAGNOSIS AND TESTING - RADIATOR
COOLANT FLOW
The following procedure will determine if coolant is
flowing through the cooling system.
If engine is cold, idle engine until normal operating
temperature is reached. Then feel the upper radiator
hose. If hose is hot, the thermostat is open and water
is circulating through cooling system.
REMOVAL
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 the solution is
clean, drain the 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. 19). ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 20). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
Fig. 19 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 18 Downflow Radiator - Typical
1 - DOWNFLOW RADIATOR
2 - INTEGRAL TRANSMISSION OIL COOLER (INTERNAL TO
RADIATOR)
TJ
ENGINE
7 - 33
FAN DRIVE VISCOUS CLUTCH (Continued)
CAUTION: When removing the radiator or A/C con-
denser for any reason, note the location of all radi-
ator-to-body and radiator-to-A/C condenser rubber
air seals (Fig. 21). These are used at the top, bot-
tom and sides of the radiator and A/C condenser.
To
prevent
overheating,
these
seals
must
be
installed to their original positions.
(1) Disconnect negative battery cable at battery.
(2) Observe the previous WARNING. Remove the
radiator cap.
(3) Remove the condenser lower seal from the
lower core support (Fig. 22).
(4) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE) drain coolant into a
clean container for reuse.
(5) Remove radiator upper and lower hose clamps.
Remove radiator hoses.
(6) Disconnect coolant reserve/overflow tank hose
from radiator.
(7) 2.4L ONLY - Remove the electric cooling fan
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(8) 4.0L ONLY - Remove the reservoir tank and
power steering reservoir and position out of the way.
(9) 4.0L ONLY - Remove the four fan shroud
mounting bolts (Fig. 23). Position the fan shroud
back over the fan blades.
(10) If equipped, disconnect and plug automatic
transmission fluid cooler lines.
(11) Remove six radiator mounting bolts. Position
the front axle vent hose (Fig. 23) to the side.
(12) The lower part of radiator is equipped with
two alignment dowel pins (Fig. 24). They are located
on the bottom of radiator tank and fit into rubber
grommets. These rubber grommets are pressed into
the radiator lower crossmember.
(13) Lift radiator straight up and out of vehicle
taking care not to damage radiator fins.
Fig. 20 Clamp Number/Letter Location - Typical
1 - TYPICAL CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - TYPICAL HOSE
Fig. 21 Air Seals - Typical
1 - AIR DAM
2 - RADIATOR
3 - AIR DAM
4 - A/C CONDENSER
5 - AIR SEAL
Fig. 22 Condenser Lower Seal
7 - 34
ENGINE
TJ
RADIATOR (Continued)
(14) When removing radiator, note position of the
rubber seals located on the top and bottom of radia-
tor (on certain models only) (Fig. 23). To prevent pos-
sible overheating, these seals must be installed to
their original positions.
CLEANING
Clean radiator fins. With the engine cold, apply
cold water and compressed air to the back (engine
side) of the radiator to flush the radiator and/or A/C
condenser of debris.
INSPECTION
The radiator cooling fins should be checked for
damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.
Fig. 23 Radiator - Remove/Install
1 - A/C CONDENSER SEALS
2 - FAN SHROUD (4.0L)
3 - FAN SHROUD (2.5L)
4 - TRANSMISSION OIL COOLER LINES RETAINER CLIPS
5 - COOLANT RECOVERY BOTTLE
6 - TRANSMISSION COOLER LINES (IF EQUIPPED)
7 - FRONT AXLE VENT HOSE
Fig. 24 Radiator Alignment Dowels - Typical
1 - RADIATOR
2 - ALIGNMENT DOWEL
3 - RADIATOR LOWER ISOLATOR
4 - RADIATOR LOWER CROSSMEMBER
TJ
ENGINE
7 - 35
RADIATOR (Continued)
INSTALLATION
CAUTION: Before installing the radiator or A/C con-
denser, be sure the radiator-to-body and radiator-to-
A/C
condenser
rubber
air
seals
are
properly
fastened to their original positions. These are used
at the top, bottom and sides of the radiator and A/C
condenser. To prevent overheating, these seals
must be installed to their original positions.
(1) Guide the two radiator alignment dowels into
the rubber grommets located in lower radiator cross-
member. Install and tighten the six mounting bolts
(Fig. 23) to 8 N·m (72 in. lbs.) torque.
(2) Close radiator draincock.
(3) 2.4L ONLY - Install the electric cooling fan
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(4) Position fan shroud and power steering reser-
voir tank (if equipped). Install and tighten four
mounting bolts to 8 N·m (72 in. lbs.) torque.
(5) If equipped, remove plugs and connect auto-
matic transmission fluid cooler lines and constant
tension clamps.
CAUTION: The tangs on the hose clamps must be
positioned straight down.
(6) Connect radiator hoses and install hose clamps.
(7) Position and install the condenser lower seal
(Fig. 22).
(8) Connect battery negative cable.
(9) Fill cooling system with correct coolant (Refer
to 7 - COOLING - STANDARD PROCEDURE).
(10) Connect coolant recovery bottle hose.
(11) Install radiator cap.
(12) Check and adjust automatic transmission
fluid level (if equipped).
(13) Start engine and check for leaks.
WATER PUMP - 2.4L
DESCRIPTION
The water pump has a cast aluminum body and
housing with a stamped steel impeller. The water
pump bolts directly to the block (Fig. 25). The cylin-
der block to water pump seal is provided by a rubber
O-ring. The water pump is driven by the engine tim-
ing belt.
OPERATION
The water pump is the heart of the cooling system.
The coolant is pumped through the engine block, cyl-
inder head, heater core, and radiator.
DIAGNOSIS AND TESTING
WATER PUMP
A quick flow test to determine if the water pump is
working effectively is to check heater system for
proper operation. A defective pump will not provide
an adequate flow of heated coolant through the sys-
tem.
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
Another flow test to help determine water pump
operation is as follows:
(1) Remove cooling system pressure cap.
(2) Remove a small amount of coolant from the
system.
(3) Start the engine and warm up until thermostat
opens.
(4) With the thermostat open and coolant level low,
visually inspect for coolant flow. If flow is present,
the water pump is pumping coolant through the sys-
tem.
Fig. 25 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
7 - 36
ENGINE
TJ
RADIATOR (Continued)
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