Dodge Dakota (R1). Manual — part 275
(4) Position thermostat housing to intake manifold.
Note the word FRONT stamped on housing (Fig. 17).
For adequate clearance, this must be placed towards
front of vehicle. The housing is slightly angled for-
ward after installation to intake manifold.
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 N·m (200 in. lbs.) torque.
(6) Install upper radiator hose to thermostat hous-
ing.
(7) Air Conditioned vehicles:
CAUTION: When installing the serpentine accessory
drive belt, the belt must be routed correctly. If not,
engine may overheat due to water pump rotating in
wrong direction. Refer to (Fig. 18) for correct engine
belt routing. The correct belt with correct length
must be used.
(a) Install generator. Tighten bolts to 41 N·m (30
ft. lbs.).
(b) Install support bracket (generator mounting
bracket-to-intake manifold) (Fig. 14). Tighten bolts
to 54 N·m (40 ft. lbs.) torque.
(c) Position drive belt over all pulleys except
idler pulley (located between generator and A/C
compressor).
(d) Attach a socket/wrench to pulley mounting
bolt of automatic tensioner (Fig. 15).
(e) Rotate socket/wrench clockwise. Place belt
over idler pulley. Let tensioner rotate back into
place. Remove wrench. Be sure belt is properly
seated on all pulleys.
(8) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
(9) Connect battery negative cable.
(10) Start and warm the engine. Check for leaks.
RADIATOR
DESCRIPTION
The radiator is a aluminum cross-flow design with
horizontal tubes through the radiator core and verti-
cal plastic side tanks (Fig. 19).
OPERATION
The radiator supplies sufficient heat transfer using
the cooling fins interlaced between the horizontal
tubes in the radaitor core to cool the engine and
automatic transmission oil (if equipped).
REMOVAL
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
(1) Disconnect battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
Fig. 16 Thermostat—5.2L/5.9L Engines
1 - THERMOSTAT HOUSING
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
Fig. 17 Thermostat Position—5.2L/5.9L Engines
7a - 46
5.2L ENGINE
R1
THERMOSTAT (Continued)
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. 20). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 21). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(3) Remove hose clamps (Fig. 20) and hoses from
radiator. Disconnect coolant reserve/overflow tank
hose and washer bottle electrical connector and hose.
Fig. 18 Belt Routing—5.2L/5.9L Engines
1 - IDLER PULLEY
2 - GENERATOR PULLEY
3 - A/C COMPRESSOR PULLEY
4 - IF W/OUT A/C
5 - POWER STEERING PUMP PULLEY
6 - WATER PUMP PULLEY
7 - CRANKSHAFT PULLEY
8 - AUTOMATIC TENSIONER
Fig. 19 Radiator - Typical
1 - RADIATOR
2 - A/C CONDENSER (IF EQUIPPED)
3 - TRANSMISSION AUXILIARY OIL COOLER
Fig. 20 Hose Clamp Tool - Typical
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 21 Clamp Number/Letter Location
1 - CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - HOSE
R1
5.2L ENGINE
7a - 47
RADIATOR (Continued)
(4) Remove upper fan shroud mounting screws Lift
upper fan shroud assembly up and out of engine com-
partment (Fig. 22).
(5) Remove front grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(6) Disconnect transmission oil cooler lines, (if
equipped) (Fig. 23).
(7) Disconnect electric cooling fan motor connector.
(8) Remove radiator upper mounting screws (Fig.
24). Lift radiator upward and away from vehicle. Do
not allow cooling fins of radiator to contact any other
vehicle component. Radiator fin damage could result.
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 con-
denser 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.
Fig. 22 Radiator Upper Fan Shroud Removal/
Installation - Typical
1 - RADIATOR
2 - ELECTRIC COOLING FAN
3 - UPPER SHROUD & WASHER RESERVOIR UNIT
4 - SCREW
5 - LOWER SHROUD
Fig. 23 Transmission Oil Cooler Lines - Automatic
Transmission Only
1 - TRANSMISSION COOLER SUPPLY LINE
2 - TRANSMISSION OIL COOLER RETURN LINE
Fig. 24 Radiator Removal/Installation - Typical
1 - CORE SUPPORT
2 - LOWER ISOLATOR MOUNTS
3 - ISOLATOR PINS
4 - RADIATOR ASSEMBLY
5 - SCREWS
7a - 48
5.2L ENGINE
R1
RADIATOR (Continued)
INSTALLATION
The radiator has two isolator pins on bottom of
both tanks. These fit into alignment holes in radiator
lower support (Fig. 24).
(1) Position isolator pins into alignment holes in
radiator lower support.
(2) Install and tighten radiator mounting bolts to
23 N·m (200 in. lbs.) (Fig. 24).
(3) Install the transmission oil cooler lines, (if
equipped).
(4) Install front grille.
(5) Connect fan motor electrical connector to har-
ness connector.
(6) Position upper fan shroud onto lower fan
shroud and radiator.
(7) Install retaining screws into shroud.
(8) Install
radiator
hoses.
reconnect
coolant
reserve/overflow tank hose.
(9) Connect battery negative cable.
(10) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(11) Start and warm the engine. Check for leaks.
RADIATOR CAP
DIAGNOSIS AND TESTING - RADIATOR CAP
PRESSURE
RADIATOR CAP-TO-FILLER NECK SEAL -
PRESSURE RELIEF CHECK
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/OVER-
FLOW 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 PRESSURE DROPS, REMOVE
RADIATOR CAP COMPLETELY.
RADIATOR CAP - PRESSURE TESTING
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. 25).
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
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.
Fig. 25 Pressure Testing Radiator Cap - Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
R1
5.2L ENGINE
7a - 49
RADIATOR (Continued)
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