A. Inspect Core Plugs and Replace Coolant

WARNING:
Do not remove the cooling system pressure cap or open the radiator draincock when the system is hot and under pressure because serious burns from coolant can occur.

1. Remove the cooling system pressure cap.

2. Install a radiator pressure tester on the coolant fill neck and apply 15 psi (104 kpa) pressure.

3. Monitor the pressure for 2 minutes. If the pressure drops more than 2 psi, visually inspect all hose connections for leaks. Tighten as necessary and repeat the pressure test.

4. Raise the vehicle on an appropriate hoist.





5. Inspect the six engine block core plugs (three on each side) for signs of coolant leakage (Figure 1).





6. Inspect the transmission bell housing for signs of coolant leakage from the rear of the cylinder block (Figure 2).





7. Inspect the bottom of the timing belt cover for signs of coolant leakage (Figure 3).

8. Lower the vehicle.

9. ^ If there is any evidence of coolant leakage from any of the core plugs in the block or heads, then ALL of the coolant related engine block and cylinder head core plugs must be replaced. Skip to Section "B -- Remove Engine and Transmission Assembly to Replace All Engine Block and Head Core Plugs".

^ If there is NO coolant leakage from any of the core plugs in the block or heads, only the coolant must be replaced. Continue with Step 10.

10. Remove the pressure tester from the filler neck.

11. Raise the vehicle on the hoist.

12. Using a 3/8" drive, 19 mm socket, 3" extension, universal joint and another extension, open the radiator draincock to drain the coolant.

CAUTION:
Use care to avoid burns from hot coolant.

13. Remove the drain plug from the rear of the engine cylinder block (Figure 1) to drain the coolant from the engine.

CAUTION:
Use care to avoid burns from hot coolant.

14. Reinstall the rear cylinder block drain plug.

15. Tighten the radiator draincock to 22 in-lbs (2.5 N.m).

16. Lower the vehicle.

17. Using a suction gun, remove the coolant from the coolant reserve tank.

18. Fill the cooling system with 1-1/3 gallons (5 liters) of Mopar coolant, and then finish filling the system with water.

CAUTION:
Do not spill coolant on the drive belts, generator or painted surfaces.

19. Fill the coolant reserve bottle with a 50/50 mix of coolant and water to at least the FULL HOT mark.

20. Start the engine and run it until the radiator fan comes on. Top off the coolant reserve bottle as necessary.

21. Return the vehicle to the customer, no further action is required.