Jeep Wrangler TJ. Manual — part 270
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - RADIATOR
CAP-TO-FILLER NECK SEAL
The pressure cap upper gasket (seal) pressure
relief can be tested by removing overflow hose from
radiator filler neck nipple. Attach hose of pressure
tester tool 7700 (or equivalent) to nipple. It will be
necessary to disconnect hose from its adapter for
filler neck. Pump air into radiator. The pressure cap
upper gasket should relieve at 69-124 kPa (10-18 psi)
and hold pressure at a minimum of 55 kPa (8 psi).
WARNING: THE WARNING WORDS - DO NOT OPEN
HOT - ON RADIATOR PRESSURE CAP, ARE A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, RADIATOR CAP SHOULD
NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR
UNDER PRESSURE.
Do not remove radiator cap at any time except for
the following purposes:
(1) Check and adjust antifreeze freeze point.
(2) Refill system with new antifreeze.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER CAP AND WITH-
OUT PUSHING CAP DOWN, ROTATE IT COUNTER-
CLOCKWISE TO FIRST STOP. ALLOW FLUID TO
ESCAPE
THROUGH
THE
COOLANT
RESERVE/
OVERFLOW
HOSE
INTO
RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE
WHEN
PRESSURE
HAS
BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
DIAGNOSIS AND TESTING - RADIATOR CAP
Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install cap on pressure tester 7700 or an equiv-
alent (Fig. 35).
Operate tester pump to bring pressure to 117 kPa
(17 psi) on gauge. If pressure cap fails to hold pres-
sure of at least 110 kPa (16 psi) replace cap. Refer to
the following CAUTION.
The pressure cap may test properly while posi-
tioned on tool 7700 (or equivalent). It may not hold
pressure or vacuum when installed on radiator. If so,
inspect radiator filler neck and cap’s top gasket for
damage. Also inspect for dirt or distortion that may
prevent cap from sealing properly.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Use only a mild soap and water to clean the radi-
ator cap. Using any type solvent may cause damage
to the seal in the radiator cap.
INSPECTION
Hold cap at eye level, right side up. The vent valve
(Fig. 34) at bottom of cap should open. If rubber gas-
ket has swollen and prevents vent valve from open-
ing, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket,
replace cap. Do not use a replacement cap that
has a spring to hold vent shut. A replacement cap
must be the type designed for a coolant reserve/over-
flow system with a completely sealed diaphragm
Fig. 35 Pressure Testing Radiator Cap - Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
TJ
ENGINE
7 - 41
RADIATOR PRESSURE CAP (Continued)
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.
RADIATOR FAN
DESCRIPTION
The electric cooling fan replaces the engine driven
mechanical fan. The electric cooling fan is integral to
the fan shroud and is located between the radiator
and the engine.
The electric fan is controlled by the electronic con-
trol module (ECM).
The electric cooling fan is not serviceable. Any fail-
ure of the fan blade, electric motor or fan shroud
requires replacement of the fan module.
CAUTION: Do not attempt to service the electric
cooling fan or fan blades separately, replace the
cooling module as an assembly. Failure to do so
may cause severe damage to the electric cooling
fan assembly.
REMOVAL
REMOVAL
(1) Remove the coolant recovery bottle and position
out of the way (Fig. 36).
(2) Remove and position the power steering reser-
voir out of the way.
(3) Disconnect the electrical connector.
(4) Remove the mounting screws.
(5) Remove the cooling fan assembly (Fig. 37).
REMOVAL - 4.0L
(1) Remove the thermal viscous fan drive/fan blade
assembly (Refer to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH - REMOVAL).
(2) Remove the four fan retaining bolts.
(3) Seperate the fan blade from the thermal vis-
cous fan drive.
CLEANING
Clean the fan blades using a mild soap and water.
Do not use an abrasive to clean the blades.
INSPECTION
WARNING:
DO
NOT
ATTEMPT
TO
BEND
OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
Fig. 36 Coolant Recovery Bottle
1 - COOLANT RECOVERY BOTTLE
2 - COOLING FAN ASSEMBLY
2 - POWER STEERING RESERVOIR
Fig. 37 Electrical Connector
1 - ELECTRICAL CONNECTOR
2 - MOUNTING SCREW
7 - 42
ENGINE
TJ
RADIATOR PRESSURE CAP (Continued)
CAUTION:
If
fan
blade
assembly
is
replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
(3) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
INSTALLATION
INSTALLATION
(1) Position the cooling fan assembly.
(2) Install four mounting screws. Tighten to 5.5
N·m (50 in. lbs.)
(3) Connect the electrical connector.
(4) Install the power steering reservoir.
(5) Install the coolant recovery bottle.
INSTALLATION - 4.0L
(1) Position the fan blade on the thermal viscous
fan drive.
(2) Install four mounting bolts. Tighten to 23 N·M
(210 in. lbs.).
(3) Install the thermal viscous fan drive (Refer to 7
-
COOLING/ENGINE/FAN
DRIVE
VISCOUS
CLUTCH - INSTALLATION).
RADIATOR FAN RELAY
DESCRIPTION
The electric cooling fan HI and LOW relays are
located in the Power Distribution Center (PDC) in
the engine compartment. See the fuse and relay lay-
out label affixed to the inside surface of the PDC
cover for cooling fan relay identification and location.
The HI and LOW cooling fan relays cannot be
adjusted or repaired. If the HI or LOW relay is dam-
aged or faulty, it must be replaced.
TJ
ENGINE
7 - 43
RADIATOR FAN (Continued)
TRANSMISSION
TABLE OF CONTENTS
page
page
TRANSMISSION COOLER
. . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION COOLER
DESCRIPTION
NOTE: The internal transmission oil cooler located
within the radiator is not serviceable. If it requires
service, the radiator must be replaced.
All models equipped with an automatic transmis-
sion are equipped with a transmission oil cooler
(water-to-oil) mounted internally within the radiator
tank (Fig. 1). This internal cooler is supplied as stan-
dard equipment on all models equipped with an auto-
matic transmission.
OPERATION
Transmission oil is cooled when it passes through
this separate cooler. In case of a leak in the internal
radiator mounted transmission oil cooler, engine cool-
ant may become mixed with transmission fluid or
transmission fluid may enter the cooling system.
Both cooling system and transmission should be
drained
and
inspected
if
the
internal
radiator
mounted transmission cooler is leaking.
Fig. 1 Radiator with Integral Transmission Oil
Cooler
1 - DOWNFLOW RADIATOR
2 - INTEGRAL TRANSMISSION OIL COOLER (INTERNAL TO
RADIATOR)
7 - 44
TRANSMISSION
TJ
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