Dodge Durango (DN). Manual — part 250

INSTALLATION

(1) Connect harness to sensor. Be sure seal is

securely in place between sensor and wiring
connector.

(2) Install O-ring on sensor (if removed).
(3) Insert sensor in differential housing.
(4) Install sensor shield.
(5) Install the sensor mounting stud and tighten to

24 N·m (200 in. lbs.).

(6) Install the brake line on the sensor stud and

install the nut.

(7) Lower vehicle.

EXCITER RING

The exciter ring is mounted on the differential

case. If the ring is damaged refer to Group 3 Differ-
ential and Driveline for service procedures.

SPECIFICATIONS

TORQUE CHART

DESCRIPTION

TORQUE

ABS Assembly

Bracket bolts . . . . . . . . 14-15 N·m (10-12 ft. lbs.)
Mounting Nuts . . . . . . . . . . 12 N·m (102 in. lbs.)
CAB Screws . . . . . . . . . 4-4.7 N·m (36-42 in. lbs.)
Brake Line Fittings . . . . . . . 19 N·m (170 in. lbs.)

Wheel Speed Sensors

Front Sensor Bolt . . . . . . . . 21 N·m (190 in. lbs.)
Rear Sensor Bolt . . . . . . . 22.5 N.m (200 in. lbs.)

Fig. 12 Tone Wheel 4x2

1 – HUB
2 – TONE WHEEL
3 – BEARING

Fig. 13 Rear Speed Sensor Mounting

1 – DIFFERENTIAL HOUSING
2 – WHEEL SPEED SENSOR

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BRAKES

5 - 47

REMOVAL AND INSTALLATION (Continued)

COOLING SYSTEM

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2
COOLANT RESERVE/OVERFLOW SYSTEM . . . . . 2
THERMOSTAT—5.2L/5.9L ENGINES . . . . . . . . . . 3
THERMOSTAT—4.7L ENGINE . . . . . . . . . . . . . . . 4
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . . . 4
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WATER PUMP BYPASS—4.7L . . . . . . . . . . . . . . . 6
WATER PUMP BYPASS HOSE—5.2L/5.9L

ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

AUTOMATIC TRANSMISSION OIL COOLERS. . . . 7
AUTOMATIC BELT TENSIONER . . . . . . . . . . . . . . 7
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . 9

DIAGNOSIS AND TESTING

ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 10
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . . 10
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . 10
ELECTRIC COOLING FAN . . . . . . . . . . . . . . . . . . 15
RADIATOR COOLANT FLOW CHECK . . . . . . . . . 16
COOLING SYSTEM—TESTING FOR LEAKS . . . . 16
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 18
ACCESSORY DRIVE BELT DIAGNOSIS. . . . . . . . 19
THERMOSTAT—GAS ENGINES . . . . . . . . . . . . . 21
RADIATOR CAP-TO-FILLER NECK

SEAL—PRESSURE RELIEF CHECK . . . . . . . . . 21

RADIATOR CAP—PRESSURE TESTING. . . . . . . 21
COOLANT—LOW LEVEL AERATION . . . . . . . . . 22
COOLING SYSTEM—DEAERATION . . . . . . . . . . 22

SERVICE PROCEDURES

COOLANT—ROUTINE LEVEL CHECK. . . . . . . . . 22
COOLANT SERVICE . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT SELECTION AND ADDITIVES . . . . . . 23

COOLANT—ADDING ADDITIONAL. . . . . . . . . . . 23
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . 23
COOLING SYSTEM—DRAINING AND

FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

COOLING SYSTEM—CLEANING/REVERSE

FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

REMOVAL AND INSTALLATION

COOLANT RESERVE/OVERFLOW TANK . . . . . . . 25
WATER PUMP—5.2L/5.9L ENGINES . . . . . . . . . 25
WATER PUMP 4.7L ENGINES . . . . . . . . . . . . . . 27
WATER PUMP BYPASS HOSE—5.2L/5.9L

ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

THERMOSTAT—5.2L/5.9L ENGINE . . . . . . . . . . 32
THERMOSTAT— 4.7L ENGINE . . . . . . . . . . . . . . 34
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 37
ACCESSORY DRIVE BELT—5.2L/5.9L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ACCESSORY BELT REPLACEMENT—4.7L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

AUTOMATIC BELT TENSIONER—5.2L/5.9L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

AUTOMATIC BELT TENSIONER—4.7L

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

RADIATOR DRAINCOCK . . . . . . . . . . . . . . . . . . . 40
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 41

CLEANING AND INSPECTION

RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . 42
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 43
FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SPECIFICATIONS

COOLING SYSTEM CAPACITIES. . . . . . . . . . . . . 43
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 44

SPECIAL TOOLS

COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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COOLING SYSTEM

7 - 1

DESCRIPTION AND OPERATION

COOLING SYSTEM

DESCRIPTION

The cooling system consists of:
• Radiator

• Cooling fan (mechanical/Electrical)

• Thermal viscous fan drive

• Fan shroud

• Radiator pressure cap

• Thermostat

• Coolant reserve/overflow system (integral to

upper fan shroud)

• Transmission oil cooler (if equipped with an

automatic transmission)

• Coolant

• Water pump

• Hoses and hose clamps

OPERATION

The cooling system regulates engine operating tem-

perature. It allows the engine to reach normal oper-

ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.

The cooling system also provides a means of heat-

ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.

An optional factory installed maximum duty cool-

ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
trailer towing in high ambient temperatures.

COOLANT RESERVE/OVERFLOW SYSTEM

DESCRIPTION

The coolant reserve/overflow tank is integral to the

upper fan shroud assembly and is made of high tem-
perature plastic.

Fig. 1 Engine Cooling System Flow—5.2L/5.9L Engines—Typical

1 – HEATER
2 – BYPASS*

3 – CROSSFLOW RADIATOR

7 - 2

COOLING SYSTEM

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