Content .. 275 276 277 278 ..

Dodge Dakota (R1). Manual - part 277

INSTALLATION

(1) Install fan blade assembly to viscous fan drive.

Tighten bolts (Fig. 34) to 23 N·m (17 ft. lbs.) torque.

(2) Position fan blade/viscous fan drive assembly

and upper shroud into vehicle.

(3) Install fan shroud retaining screws (Fig. 35).

(4) Install fan blade/viscous fan drive assembly to

water pump shaft (Fig. 33).

(5) Connect battery negative cable.

WATER PUMP

DESCRIPTION

The water pump is located on the engine front

cover, and has an integral pulley attached (Fig. 36).

The water pump impeller is pressed onto the rear

of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ven-
tilation. The water pump seals are lubricated by
antifreeze in the coolant mixture. Additional lubrica-
tion is not necessary.

OPERATION

centrifugal

water

pump

circulates

coolant

through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core,
this coolant absorbs the heat generated when the
engine is running. The pump is driven by the engine
crankshaft via a drive belt.

REMOVAL

The water pump can be removed and installed

without discharging the air conditioning system (if
equipped).

(1) Disconnect battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(3) Do not waste reusable coolant. If solution is

clean, drain 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. 42). 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. 43). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.

(4) Remove upper radiator hose clamp and hose at

radiator.

(5) The thermal viscous fan drive is attached

(threaded) to the water pump hub shaft (Fig. 38).
Remove fan/viscous fan drive assembly from water
pump by turning mounting nut counterclockwise as
viewed from front. Threads on viscous fan drive are
RIGHT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool

Fig. 35 Upper Fan Shroud Removal/Installation

1 - RADIATOR
2 - ELECTRIC COOLING FAN
3 - UPPER SHROUD & WASHER RESERVOIR UNIT
4 - SCREW
5 - LOWER SHROUD

Fig. 36 Water Pump Location - Typical

1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY

7a - 54

5.2L ENGINE

VISCOUS FAN DRIVE (Continued)

Set number 2017DSP) and Special Tool 6958 Span-
ner Wrench with Adapter Pins 8346 can be used.
Place Special Tool 6958 Spanner Wrench onto the
water pump pulley with Adapter Pins 8346 inserted
into the holes on the pulley (Fig. 37) to prevent pul-
ley from rotating. Do not attempt to remove fan/vis-
cous fan drive assembly from vehicle at this time.

(6) If water pump is being replaced, do not unbolt

fan blade assembly (Fig. 38) from thermal viscous
fan drive.

(7) Remove fan shroud attaching hardware (two

bolts at bottom-two clips at top).

(8) Remove fan shroud and fan blade/viscous fan

drive assembly from vehicle as a complete unit.

(9) After removing fan blade/viscous fan drive

assembly, do not place thermal viscous fan drive in
horizontal position. If stored horizontally, silicone
fluid in viscous fan drive could drain into its bearing
assembly and contaminate lubricant.

(10) Remove accessory drive belt as follows: The

drive belt is equipped with a spring loaded automatic
tensioner (Fig. 39). Relax tension from belt by rotat-
ing tensioner clockwise (as viewed from front) (Fig.
39). When all belt tension has been relaxed, remove
accessory drive belt.

(11) Remove lower radiator hose clamp and remove

lower hose at water pump.

(12) Remove heater hose clamp and heater hose

from heater hose coolant return tube.

(13) Loosen

heater

hose

coolant

return

tube

mounting bolt (Fig. 40) and remove tube from water
pump. Discard the old tube O-ring.

(14) Remove seven water pump mounting bolts.

Fig. 37 Viscous Fan Drive Removal / Installation

1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 - FAN

Fig. 38 Fan Blade and Viscous Fan Drive - 5.2L/5.9L

Engines

1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY

Fig. 39 Automatic Belt Tensioner Assembly -

5.2L/5.9L Engines

1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE

5.2L ENGINE

7a - 55

WATER PUMP (Continued)

(15) Loosen clamp at water pump end of bypass

hose (Fig. 38). Slip bypass hose from water pump
while removing pump from vehicle. Discard old gas-
ket.

CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.

CLEANING

Clean the gasket mating surface. Use caution not

to damage the gasket sealing surface.

INSPECTION

Inspect the water pump assembly for cracks in the

housing, Water leaks from shaft seal, Loose or rough
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.

INSTALLATION

(1) Clean gasket mating surfaces.
(2) Using a new gasket, install water pump to

engine as follows: Guide water pump nipple into
bypass hose as pump is being installed. Install water
pump bolts. Tighten water pump mounting bolts to
40 N·m (30 ft. lbs.) torque.

(3) Position bypass hose clamp to bypass hose.
(4) Spin water pump to be sure that pump impel-

ler does not rub against timing chain case/cover.

(5) Install a new O-ring to the heater hose coolant

return tube (Fig. 40). Coat the new O-ring with anti-
freeze before installation.

(6) Install coolant return tube and its mounting

bolt to engine (Fig. 40). Be sure the slot in tube
bracket is bottomed to mounting bolt. This will prop-
erly position return tube.

(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to coolant

return tube.

(9) Relax tension from belt tensioner (Fig. 39).

Install accessory drive belt.

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. 47) for correct belt
routing. The correct belt with correct length must
be used.

WATER PUMP BYPASS HOSE

DESCRIPTION

A rubber water pump bypass hose (Fig. 41) is used

between the intake manifold and water pump on all
5.2L/5.9L engines.

Fig. 40 Coolant Return Tube - 5.2L/5.9L Engines -

Typical

1 - COOLANT RETURN TUBE
2 - WATER PUMP
3 - TUBE MOUNTING BOLT
4 - O-RING

Fig. 41 Water Pump Bypass Hose - 5.2L/5.9L

Engines

1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY

7a - 56

5.2L ENGINE

WATER PUMP (Continued)

OPERATION

When the thermostat is in the closed position the

bypass hose allows the water pump to circulate the
engine coolant through the cylinder block while at
the same time preventing the coolant from flowing
through the radiator, this allows the coolant to heat
up quicker thus bring the engine to operating tem-
perature faster.

REMOVAL

WITHOUT AIR CONDITIONING

(1) Partially drain cooling system (Refer to 7 -

COOLING/ENGINE - STANDARD PROCEDURE).
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.

CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 43). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.

(2) Loosen both bypass hose clamps (Fig. 42) and

position to center of hose. Remove hose from vehicle.

WITH AIR CONDITIONING

If equipped with A/C, the generator and A/C com-

pressor along with their common mounting bracket
(Fig. 44) must be partially removed. Removing gener-
ator or A/C compressor from their mounting bracket
is not necessary. Also, discharging A/C system is not
necessary. Do not remove any refrigerant lines from
A/C compressor.

WARNING: THE A/C SYSTEM IS UNDER PRESSURE
EVEN WITH ENGINE OFF. REFER TO REFRIGER-
ANT WARNINGS IN GROUP 24, HEATING AND AIR
CONDITIONING.

(1) Disconnect battery negative cable.

Fig. 42 Hose Clamp Tool - Typical

1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP

Fig. 43 Clamp Number/Letter Location

1 - CONSTANT TENSION HOSE CLAMP
2 - CLAMP NUMBER/LETTER LOCATION
3 - HOSE

Fig. 44 Generator - A/C Compressor Mounting

Bracket - 5.2L/5.9L Engine

1 - IDLER PULLEY BUSHING
2 - A/C AND/OR GENERATOR MOUNTING BRACKET
3 - IDLER PULLEY
4 - SCREW AND WASHER

5.2L ENGINE

7a - 57

WATER PUMP BYPASS HOSE (Continued)

Content .. 275 276 277 278 ..