Refilling Cooling System

REFILLING COOLING SYSTEM

Funnel that helps keep air out


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




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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.