Jeep XJ. Manual - part 72

gauge. Use the correct gauge when checking belt ten-
sion. Place gauge in the middle of the section of belt
being tested (between two pulleys) to check tension.
Do not allow the gauge (or gauge adapter) to contact
anything but the belt.

BELT SCHEMATICS

The belt routing schematics are published from the

latest information available at the time of publica-
tion. If anything differs between these schemat-
ics

and

the

Belt

Routing

Label,

use

the

schematics on Belt Routing Label. This label is
located in the engine compartment.

Refer to (Fig. 47) (Fig. 48) (Fig. 49) (Fig. 50) for

proper belt routing on vehicles with conventional left
hand drive. Refer to (Fig. 51) (Fig. 52) for proper belt
routing on vehicles with right hand drive (RHD). Or,
refer to the Belt Routing Label located in the vehicle
engine compartment.

BELT REPLACEMENT OR ADJUSTMENT—LEFT
HAND DRIVE

Belt tension is adjusted at the power steering

pump bracket and idler pulley assembly.

(1) Disconnect negative battery cable from battery.
(2) Loosen idler pulley bolt at the power steering

bracket (Fig. 53).

(3) Loosen adjusting bolt until belt can be removed

from pulleys.

(4) Remove belt.

INSTALLATION

(1) Check condition of all pulleys.

CAUTION: When installing the serpentine acces-
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
47) (Fig. 48) (Fig. 49) (Fig. 50) for correct belt rout-
ing.

Fig. 47 Models with 2.5L Engine—With A/C

Fig. 48 Models with 2.5L Engine—Without A/C

Fig. 49 Models with 4.0L Engine—Without A/C—

Except RHD

7 - 36

COOLING SYSTEM

REMOVAL AND INSTALLATION (Continued)

(2) Install new belt.
(3) Using serpentine belt tension gauge, tighten

adjusting bolt until belt reaches proper tension. Refer
to Belt Tension at the rear of this section for proper
belt tension.

(4) After belt is tensioned correctly, tighten idler

pulley bolt to 47 N·m (35 ft. lbs.)

(5) After idler pulley has been tightened into posi-

tion, recheck belt tension. Adjust if necessary.

BELT REPLACEMENT OR ADJUSTMENT—RIGHT
HAND DRIVE (4.0L)

(1) Disconnect negative battery cable from battery.
(2) Loosen lower alternator mounting bolt and nut.

(3) Loosen upper alternator mounting nut.
(4) Loosen adjusting bolt at upper alternator bracket

(Fig. 54) until belt can be removed from pulleys.

(5) Remove belt.

INSTALLATION

(1) Check condition of all pulleys.

Fig. 50 Models With 4.0L Engine—With A/C—Except

RHD

Fig. 51 Models With 4.0L Engine—With A/C—With

RHD

Fig. 52 Models With 4.0L Engine—Without A/C—

With RHD

Fig. 53 Power Steering Pump Bracket and Idler

Pulley

1 – ADJUSTING BOLT
2 – IDLER PULLEY BOLT

COOLING SYSTEM

7 - 37

REMOVAL AND INSTALLATION (Continued)

(2) Install new belt.
(3) Using serpentine belt tension gauge, tighten

adjusting bolt until belt reaches proper tension. Refer
to Belt Tension at the rear of this section for proper
belt tension.

(4) Tighten alternator upper and lower mounting

bolts.

(5) After generator and adjust bracket have been

tightened into position, recheck belt tension. Adjust if
necessary.

COOLING SYSTEM FANS

REMOVAL

Some engines have the mechanical fan/viscous fan

drive assembly mounted directly to the water pump
hub (Fig. 55). It may also be mounted to a hub/bear-
ing attached to an aluminum bracket on the right
front side of engine (Fig. 56).

(1) Loosen but do not remove at this time, the four

fan hub mounting nuts (Fig. 55) (Fig. 56).

(2) Remove accessory serpentine drive belt. Refer

to Belt Service in the Engine Accessory Drive Belt
section of this group.

(3) Some models with certain engines may require

the removal of the fan shroud to remove the viscous
fan drive. The fan shroud and fan blade/viscous fan

drive should be removed from the vehicle as one
assembly.

(4) Remove four fan hub mounting nuts (Fig. 55)

(Fig. 56) and remove fan/viscous fan drive assembly
from vehicle.

(5) 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.

INSTALLATION

(1) Assemble fan blade to viscous fan drive.

Tighten mounting bolts to 27 N·m (20 ft. lbs.) torque.

(2) Position mounting flange of fan blade/viscous

fan drive assembly onto hub. Install four nuts and
tighten to 24 N·m (18 ft. lbs.) torque. Tighten the
first two nuts 180 degrees apart. Then tighten last
two nuts.

CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. Refer to appropriate
Engine Accessory Drive Belt Schematic in this
group for correct belt routing.

Fig. 54 Generator Belt Tension Adjust Bracket

1 – TENSION ADJUSTMENT BOLT
2 – UPPER ALTERNATOR NUT

Fig. 55 Water Pump Mounted Cooling Fan

1 – THERMAL VISCOUS FAN DRIVE
2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 – (4) FAN HUB-TO-PUMP PULLEY STUDS
4 – WATER PUMP
5 – WATER PUMP PULLEY
6 – FAN BLADE
7 – (4) FAN HUB-TO-PUMP PULLEY NUTS

7 - 38

COOLING SYSTEM

REMOVAL AND INSTALLATION (Continued)

(3) Install accessory drive belts. Tension belts to

specifications. Refer to the Specifications section at
the end of this group.

VISCOUS FAN DRIVE REMOVAL/INSTALLATION

Refer to Cooling System Fan for removal and

installation procedures of the viscous drive unit.

Viscous Fan Drive Fluid Pump Out Requirement:

After installing a new viscous fan drive, bring the

engine speed up to approximately 2000 rpm and hold
for approximately two minutes. This will ensure
proper fluid distribution within the drive.

CLEANING AND INSPECTION

RADIATOR PRESSURE CAP

CLEANING

Clean the radiator pressure cap using a mild soap

and water only.

INSPECTION

Visually inspect the pressure valve gasket on the

cap. Replace cap if the gasket is swollen, torn or
worn. Inspect the area around radiator filler neck for
white deposits that indicate a leaking cap.

RADIATOR

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.

Inspect the radiator neck for damage or distortion.

WATER PUMP

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.

FAN BLADE

CLEANING

Clean the fan blades using a mild soap and water.

Do not use an abrasive to clean the blades.

INSPECTION

WARNING: DO

NOT

ATTEMPT

BEND

STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.

CAUTION: If

fan

blade

assembly

replaced

because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.

(1) Remove fan blade assembly from viscous fan

drive unit (four bolts).

(2) Lay fan on a flat surface with leading edge fac-

ing down. With tip of blade touching flat surface,
replace fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.

Fig. 56 Bracket Mounted Cooling Fan

1 – WATER PUMP (2.5L ENGINE)
2 – HUB/BEARING (4.0L ENGINE)
3 – PULLEY NUTS
4 – PULLEY
5 – BRACKET

COOLING SYSTEM

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REMOVAL AND INSTALLATION (Continued)

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