2007 Commander XK Factory Service Manual 7 - COOLING

STANDARD PROCEDURE

DRAINING COOLING SYSTEM



WARNING: Do not remove the cylinder block drain plugs or loosen the radiator draincock with system hot and under pressure. Serious burns from coolant can occur.


1. DO NOT remove radiator cap first. With engine cold, raise vehicle on a hoist and locate radiator draincock.

NOTE: Radiator draincock is located on the right/lower side of radiator facing to rear of vehicle.


2. Attach one end of a hose to the draincock. Put the other end into a clean container. Open draincock and drain coolant from radiator. This will empty the coolant reserve/overflow tank. The coolant does not have to be removed from the tank unless the system is being refilled with a fresh mixture. When tank is empty, remove radiator cap and continue draining cooling system.

REFILLING COOLING SYSTEM


3.7L


1. Tighten the radiator draincock and the cylinder block drain plug(s) (if removed).

CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe engine damage.


2. Fill cooling system with the antifreeze mixture (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). Fill pressure bottle to service line and install cap.

NOTE: The engine cooling system will push any remaining air into the coolant bottle within about an hour of normal driving. As a result, a drop in coolant level in the pressure bottle may occur. If the engine cooling system overheats and pushes coolant into the overflow side of the coolant bottle, this coolant will be sucked back into the cooling system ONLY IF THE PRESSURE CAP IS LEFT ON THE BOTTLE. Removing the pressure cap breaks the vacuum path between the two bottle sections and the coolant will not return to cooling system.


3. With heater control unit in the HEAT position, operate engine with pressure bottle cap in place.
4. Add coolant to pressure bottle as necessary. Only add coolant to the pressure bottle when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.

4.7L




1. Tighten the radiator draincock and the cylinder block drain plug(s) (if removed).

CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe engine damage.


2. Remove the cooling system bleed plug from the radiator upper hose inlet housing. Fill cooling system with the antifreeze mixture (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION), until coolant begins coming out of the cooling system bleed hole. Install the cooling system bleed plug. Fill radiator to top and install radiator cap. Add sufficient coolant to the reserve/overflow tank to raise level to FULL mark.
3. With heater control unit in the HEAT position, operate engine with radiator cap in place.
4. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the reserve/overflow tank.
5. Add coolant to reserve/overflow tank as necessary. Only add coolant to the reserve/overflow tank when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. To purge the cooling system of all air, this heat up/cool down cycle (adding coolant to cold engine) must be performed three times. Add necessary coolant to raise tank level to the FULL mark after each cool down period.

5.7L


1. Close radiator draincock. Hand tighten only.
2. Install engine block drain plugs, if removed. Coat the threads with Mopar® Thread Sealant with Teflon.

WARNING: When installing drain hose to air bleed valve, route hose away from accessory drive belts, accessory drive pulleys, and electric cooling fan motors.

NOTE: It may be necessary to install a bleed fitting on the 5.7L engine.


3. Attach a 1.5 - 2 m (4 - 6 ft.) long 6 mm (1/4 inch.) ID clear hose to bleeder fitting
  • Plug Location (5.7L): Located on the front of the water outlet housing at the front of engine.

4. Route hose away from the accessory drive belt, drive pulleys and electric cooling fan. Place the other end of hose into a clean container. The hose will prevent coolant from contacting the accessory drive belt when bleeding the system during the refilling operation.

NOTE: It is imperative that the cooling system air bleed valve be opened before any coolant is added to the cooling system. Failure to open the bleed valve first will result in an incomplete fill of the system.


5. 5.7L ENGINE - Install a threaded and barbed fitting (1/4 - 18 npt) into water pump housing.
6. Attach Filling Aid Funnel Tool 8195 to pressure bottle filler neck.
7. Using hose pinch-off pliers, pinch overflow hose that connects between the two chambers of the coolant bottle (2).
8. Open bleed fitting.
9. Pour the coolant (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION) into the larger section of Filling Aid Funnel (the smaller section of funnel is to allow air to escape).
10. Slowly fill the cooling system until a steady stream of coolant flows from the hose attached to the bleed valve.
11. Close the bleed valve and continue filling system to the top of the Filling Aid Funnel Tool 8195.
12. Remove pinch-off pliers from overflow hose.
13. Allow the coolant in Filling Funnel to drain into overflow chamber of the pressure bottle.
14. Remove Filling Aid Funnel Tool 8195. Install cap on coolant pressure bottle.
15. Remove hose from bleed valve.
16. Install fitting into thermostat housing. Coat the threads with Mopar® Thread Sealant with Teflon.
17. Start engine and run at 1500 - 2000 RPM for 30 minutes.

NOTE: The engine cooling system will push any remaining air into the coolant bottle within about an hour of normal driving. As a result, a drop in coolant level in the pressure bottle may occur. If the engine cooling system overheats and pushes coolant into the overflow side of the coolant bottle, this coolant will be sucked back into the cooling system ONLY IF THE PRESSURE CAP IS LEFT ON THE BOTTLE. Removing the pressure cap breaks the vacuum path between the two bottle sections and the coolant will not return to cooling system.


18. Shut off engine allow it to cool down for 30 minutes. This permits coolant to be drawn into the pressure chamber.
19. With engine COLD, observe coolant level in pressure chamber. Coolant level should be within MIN and MAX marks. Adjust coolant level as necessary.

REFILLING COOLING SYSTEM - 3.0L DIESEL




1. Tighten the radiator draincock and the cylinder block drain plug(s) (if removed).
2. Remove thermostat housing bleed hose from two clips .


3. Hold the thermostat housing bleed hose up so that air can flow up to bottle.

CAUTION: Failure to purge air from the cooling system can result in an overheating condition and severe engine damage.


4. Fill cooling system with the antifreeze mixture (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). Fill pressure bottle to service line and install cap.

NOTE: The engine cooling system will push any remaining air into the coolant bottle within about an hour of normal driving. As a result, a drop in coolant level in the pressure bottle may occur. If the engine cooling system overheats and pushes coolant into the overflow side of the coolant bottle, this coolant will be sucked back into the cooling system ONLY IF THE PRESSURE CAP IS LEFT ON THE BOTTLE. Removing the pressure cap breaks the vacuum path between the two bottle sections and the coolant will not return to cooling system.


5. With heater control unit in the HEAT position, operate engine with pressure bottle cap in place.
6. Add coolant to pressure bottle as necessary. Only add coolant to the pressure bottle when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.
7. Reinstall the thermostat housing bleed hose in the two clips .

ADDING ADDITIONAL COOLANT

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar® Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: Do not use coolant additives that are claimed to improve engine cooling.

REVERSE FLUSHING

CAUTION: The cooling system normally operates at 97-124 kPa (14-18 psi) pressure. Exceeding this pressure may damage the radiator or hoses.

Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done using air pressure in the opposite direction of normal coolant flow. It is usually only necessary with very dirty systems with evidence of partial plugging.


CHEMICAL CLEANING

If visual inspection indicates the formation of sludge or scaly deposits, use a radiator cleaner (Mopar Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid the flushing operation.

CAUTION: Be sure instructions on the container are followed.


REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator fittings. Attach a section of radiator hose to the radiator bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the flushing gun.

CAUTION: The cooling system normally operates at 97-124 kPa (14-18 psi) pressure. Exceeding this pressure may damage the radiator or hoses.

Allow the radiator to fill with water. When radiator is filled, apply air in short blasts allowing radiator to refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. For more information, refer to operating instructions supplied with flushing equipment. Have radiator cleaned more extensively by a radiator repair shop.


REVERSE FLUSHING ENGINE

Drain the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). Remove the thermostat housing and thermostat. Install the thermostat housing. Disconnect the radiator upper hose from the radiator and attach the flushing gun to the hose. Disconnect the radiator lower hose from the water pump. Attach a lead away hose to the water pump inlet fitting.

CAUTION: Be sure that the heater control valve is closed (heat off). This is done to prevent coolant flow with scale and other deposits from entering the heater core.

Connect the water supply hose and air supply hose to the flushing gun. Allow the engine to fill with water. When the engine is filled, apply air in short blasts, allowing the system to fill between air blasts. Continue until clean water flows through the lead away hose. For more information, refer to operating instructions supplied with flushing equipment.

Remove the lead away hose, flushing gun, water supply hose and air supply hose. Remove the thermostat housing (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL). Install the thermostat and housing with a replacement gasket (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - INSTALLATION). Connect the radiator hoses. Refill the cooling system with the correct antifreeze/water mixture (Refer to 7 - COOLING - STANDARD PROCEDURE).