1994 JEEP CHEROKEE coolant

The coolant reserve/overflow system consists of a
radiator mounted pressurized cap, a plastic reserve/
overflow tank (Figs. 21, 22 or 23), a tube connecting
the radiator and tank, and an overflow tube on the
side of the tank.
TANK REMOVAL/INSTALLATION
(1) Remove the tube clamp at the tank and remove
tube.(2) On YJ models, remove the windshield washer
reservoir and its mounting bracket.
(3) Remove the tank mounting bolts and remove
tank.
(4) Reverse the preceding steps for installation.
RADIATOR PRESSURE CAP
All radiators are equipped with a pressure cap.
This cap releases pressure at some point within a
range of 83-110 kPa (12-16 psi). The pressure relief
point (in pounds) is engraved on top of the cap (Fig.
24).
The cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi-
ator cooling capacity. The cap (Fig. 24) contains a
spring-loaded pressure relief valve. This valve opens
when system pressure reaches the release range of
83-110 kPa (12-16 psi).
A vent valve in the center of the cap allows a small
coolant flow through the cap when coolant is below
boiling temperature. The valve is completely closed
when boiling point is reached. As coolant cools, it
contracts and creates a vacuum in the cooling sys-
tem. This causes the vacuum valve to open and cool-
ant in reserve/overflow tank to be drawn through
connecting hose into radiator. If the vacuum valve is
stuck shut, radiator hoses will collapse on cool-down.
A rubber gasket seals the radiator filler neck. This
is done to maintain vacuum during coolant cool-down
and to prevent leakage when system is under pres-
sure.
Fig. 21 Reserve/Overflow TankÐYJ Models
Fig. 22 Reserve/Overflow TankÐXJ ModelsÐExcept
Right Hand Drive
Fig. 23 Reserve/Overflow TankÐXJ ModelsÐWith
Right Hand Drive
7 - 20 COOLING SYSTEMJ

RADIATOR CAP-TO-FILLER NECK
SEALÐPRESSURE RELIEF CHECK
With radiator cap installed on filler neck, remove
coolant reserve/ overflow tank hose from nipple on
filler neck. Connect a hand operated vacuum pump
to nipple. Operate pump until a reading of 47-to-61
kPa (14-to-18 in. Hg) appears on gauge. If the read-
ing stays steady, or drops slightly and then remains
steady, the pressure valve seal is good. Replace radi-
ator cap if reading does not hold.
WARNING: THE WARNING WORDS -DO NOT OPEN
HOT- ON THE RADIATOR PRESSURE CAP (FIG. 24)
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.
There is no need to remove the radiator capexcept
for the following purposes:
(1) To check and adjust antifreeze freeze point.
(2) To refill system with new antifreeze.
(3) For conducting service procedures.
(4) When checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIA-TOR UPPER HOSE TO CHECK IF SYSTEM IS UN-
DER PRESSURE. PLACE A RAG OVER THE CAP
AND WITHOUT PUSHING DOWN, ROTATE CAP
COUNTER-CLOCKWISE TO THE FIRST STOP. AL-
LOW FLUID TO ESCAPE THROUGH OVERFLOW
HOSE INTO COOLANT RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO DE-
TERMINE WHEN PRESSURE HAS BEEN RE-
LEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
PRESSURE TESTING RADIATOR CAPS
Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install the cap on pressure tester (tool 7700 or
an equivalent) (Fig. 25).
Operate the tester pump and observe the gauge
pointer at its highest point. The cap release pressure
should be 83-to-110 kPa (12-to-16 psi). The cap is sat-
isfactory when the pressure holds steady. It is also
good if it holds pressure within the 83-to-110 kPa
(12-to-16 psi) range for 30 seconds or more. If the
pointer drops quickly, replace the cap.
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.
Fig. 24 Radiator Pressure Cap
Fig. 25 Pressure Testing Radiator Pressure Cap
JCOOLING SYSTEM 7 - 21

RADIATORS
GENERAL INFORMATION
All radiators are down flow types except XJ models
with 4.0L engines. Radiators in XJ models equipped
with the 4.0L six-cylinder engine, are the cross flow
type. Plastic tanks are used on all radiators.
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches.
If plastic tank has been damaged, plastic tank
and/or O-rings are available for service repair. Tank
replacement should be done by qualified personal
with proper equipment.
RADIATOR COOLANT FLOW CHECK
The following procedure will determine if coolant is
flowing through the cooling system.
If engine is cold, idle engine until normal operating
temperature is reached. Then feel the upper radiator
hose. If hose is hot, the thermostat is open and water
is circulating through cooling system.
RADIATOR REMOVAL/INSTALLATION
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS, RADIATOR CAP, OR
LOOSEN THE RADIATOR DRAINCOCK WITH THE
SYSTEM HOT AND PRESSURIZED. SERIOUS
BURNS FROM THE COOLANT CAN OCCUR.
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 (NUM-
BER 6094) (FIG. 26). SNAP-ON CLAMP TOOL (NUM-
BER HPC-20) MAY BE USED FOR LARGER
CLAMPS. ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
XJ MODELS WITH 2.5L ENGINE
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Observe the previousWARNINGS.Remove ra-
diator cap.(3) Position drain pan under draincock. Open radi-
ator draincock. Drain radiator.
(4) Remove radiator upper and lower hose clamps
and hoses.
(5) Remove alignment dowel E-clip from radiator
lower mounting bracket (Fig. 27).
(6) Disconnect coolant reserve/overflow tank hose
from radiator.
(7) Remove radiator fan shroud mounting bolts
(Fig. 28). Push shroud back against front of engine.
(8) If equipped, disconnect and plug automatic
transmission fluid cooler lines.
(9) Remove radiator top mounting bolts (Fig. 28).
(10) Remove the radiator grille mounting screws.
Remove grille (Fig. 29).
(11) Remove the air conditioning condenser-to-ra-
diator mounting bolt. Use an open end wrench to re-
Fig. 26 Hose Clamp ToolÐTypical
Fig. 27 Radiator Remove/InstallÐXJ ModelsÐ2.5L
Engine
7 - 22 COOLING SYSTEMJ

move bottom bolts (Fig. 30).
(12) Lift radiator straight up and out of vehicle.
Take care not to damage radiator fins.
INSTALLATION
(1) Install radiator behind air conditioning con-
denser with bottom alignment dowel inserted into ra-
diator lower mounting bracket.
(2) Install E-clip to alignment dowel.(3) Tighten the four condenser-to-radiator mount-
ing bolts to 6.2 Nzm (55 in. lbs.) torque.
(4) Install radiator grille.
(5) Tighten radiator top mounting bolts to 6 Nzm
(55 in. lbs.) torque.
(6) If equipped, connect automatic transmission
fluid cooler lines to radiator.
(7) Install the radiator fan shroud. Connect the
coolant reserve/overflow tank hose.
(8) Connect radiator hoses and install hose clamps.
(9) Connect negative battery cable.
(10) Close the draincock.
(11) Fill cooling system with correct coolant.
(12) Install radiator cap.
(13) Check and adjust automatic transmission fluid
level (if equipped).
XJ MODELS WITH 4.0L ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
Fig. 28 Shroud Remove/InstallÐXJ Models With
2.5L Engine
Fig. 29 Grille Remove/InstallÐCherokee Models
With 2.5L Engine
Fig. 30 Condenser Mounting BoltsÐXJ Models With
2.5L Engine
JCOOLING SYSTEM 7 - 23

(7) If equipped, connect automatic transmission
fluid cooler lines. If equipped with remote cooler, at-
tach cooler line to bracket at bottom of radiator.
(8) Install electric cooling fan (if equipped). Insert
alignment tabs at bottom of fan shroud into slots in
bracket at bottom of radiator. Tighten mounting
bolts to 4 Nzm (36 in. lbs.) torque.
(9) Connect electric cooling fan electrical connec-
tor.(10) Install mechanical cooling fan shroud. Insert
alignment tabs at bottom of shroud into slots in
bracket at bottom of radiator. Tighten mounting
bolts to 4 Nzm (36 in. lbs.) torque (Fig. 32).
(11) Close radiator draincock.
(12) Install grille.
(13) Connect negative battery cable.
(14) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(15) Install pressure cap.
(16) Check and adjust automatic transmission fluid
level (if equipped).
YJ MODELS
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
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 (NUM-
BER 6094) (FIG. 26). SNAP-ON CLAMP TOOL (NUM-
BER HPC-20) MAY BE USED FOR LARGER
CLAMPS. ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Observe the previousWARNINGS.Remove
the radiator cap.
(3) Position drain pan under draincock. Open radi-
ator draincock and drain radiator.
(4) Remove radiator upper and lower hose clamps
and hoses.
(5) Disconnect coolant reserve/overflow tank hose
from radiator.
(6) Remove fan shroud bolts and push shroud back
onto fan (Fig. 35).
(7) If equipped, disconnect and plug automatic
transmission fluid cooler lines.
(8) Remove radiator attaching bolts.
(9) Lift radiator straight up and out of vehicle tak-
ing care not to damage radiator fins.
Fig. 33 Condenser-to-Radiator Mounting
BracketsÐXJ with 4.0L Engine
Fig. 34 Radiator InstallationÐXJ Models with 4.0L
Engine
JCOOLING SYSTEM 7 - 25

INSTALLATION
(1) Install the radiator. Tighten the mounting bolts
to8Nzm (6 ft. lbs.) torque (Fig. 35).
(2) Close radiator draincock.
(3) Install fan shroud. Tighten mounting bolts to
16 Nzm (11 ft. lbs.) torque.
(4) If equipped, remove plugs and connect auto-
matic transmission fluid cooler lines.
(5) Connect radiator hoses and install hose clamps.
(6) Connect negative battery cable.
(7) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(8) Connect reserve/overflow tank hose.
(9) Install radiator cap.
(10) Check and adjust automatic transmission fluid
level (if equipped).
COOLING SYSTEM HOSES
Rubber hoses route coolant to and from the radia-
tor, intake manifold and heater core. All XJ models
equipped with air conditioning have a coolant control
valve. This is located in-line with the heater core in-
let and outlet hoses. It controls coolant flow to the
heater core when the air conditioning system is in
operation.
Radiator lower hoses are spring-reinforced to pre-
vent collapse from water pump suction at moderate
and high engine speeds.
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 (NUM-
BER 6094) (FIG. 36). SNAP-ON CLAMP TOOL (NUM-
BER HPC-20) MAY BE USED FOR LARGER
CLAMPS. ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
Inspect the hoses at regular intervals. Replace
hoses that are cracked, feel brittle when squeezed, or
swell excessively when the system is pressurized.
For all vehicles: In areas where specific routing
clamps are not provided, be sure that hoses are posi-
tioned with sufficient clearance. Check clearance
from exhaust manifolds and pipe, fan blades, drive
belts and sway bars. Improperly positioned hoses can
be damaged, resulting in coolant loss and engine
overheating.
Ordinary worm gear type hose clamps (when
equipped) can be removed with a straight screw-
driver or a hex socket.To prevent damage to
hoses or clamps, the hose clamps should be
tightened to 4 Nzm (34 in. lbs.) torque. Do not
over tighten hose clamps.
When performing a hose inspection, inspect the ra-
diator lower hose for proper position and condition of
the internal spring.
COOLING SYSTEM FANS
All models are equipped with a mechanical temper-
ature controlled fan. The viscous fan drive is a
torque-and-temperature-sensitive clutch unit. It auto-
matically increases or decreases fan speed to provide
proper engine cooling. XJ models equipped with a
4.0L engine may also have an auxiliary electrical
fan. This is with models that have air conditioning
and/or heavy duty cooling.
VISCOUS FAN DRIVE OPERATION
The viscous fan drive (Fig. 37) is a silicone-fluid-
filled coupling. On some engines it connects the fan
assembly to the fan/water pump pulley. The coupling
allows the fan to be driven in a normal manner. This
is done at low engine speeds while limiting the top
Fig. 35 RadiatorÐRemove/InstallÐYJ Models
Fig. 36 Hose Clamp ToolÐTypical
7 - 26 COOLING SYSTEMJ

speed of the fan to a predetermined maximum level
at higher engine speeds. A bimetallic spring coil is
located on the front face. This spring coil reacts to
the temperature of the radiator discharge air. It en-
gages the viscous fan drive for higher fan speed if
the air temperature from the radiator rises above a
certain point. Until additional engine cooling is nec-
essary, the fan will remain at a reduced rpm regard-
less of engine speed.
Only when sufficient heat is present, will the vis-
cous fan drive engage. This is when the air flowing
through the radiator core causes a reaction from the
bimetallic coil. It then increases fan speed to provide
the necessary additional engine cooling.
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again re-
acts and the fan speed is reduced to the previous dis-
engaged speed.
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
VISCOUS FAN DRIVE TEST
The cooling system must be in good condition. This
is checked prior to performing the following test. It
also will ensure against excessively high coolant
temperature.
CAUTION: Be sure that there is adequate fan blade
clearance before drilling.(1) Drill a 3.18-mm (1/8-in) diameter hole in the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
(or equivalent). It should have a range of -18É-to-
105ÉC (0É-to-220É F). Insert thermometer through the
hole in the shroud. Be sure that there is adequate
clearance from the fan blades.
(3) Connect a tachometer and an engine ignition
timing light (timing light is to be used as a strobe
light).
(4) Block the air flow through the radiator. Secure
a sheet of plastic in front of the radiator (or air con-
ditioner condenser). Use tape at the top to secure the
plastic and be sure that the air flow is blocked.
(5) Be sure that the air conditioner (if equipped) is
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engine and operate at 2400 rpm with
the timing light (strobe light) aimed at the fan
blades. Within ten minutes the air temperature (in-
dicated on the dial thermometer) should be 88É C
(190É F). Satisfactory operation of the fan drive re-
quires that it engage before or at 88É C (190É F). En-
gagement is distinguishable by a definite increase in
flow noise. The timing light also will indicate an in-
crease in the speed of the fan.
(7) When the air temperature reaches 88É C (190É
F), remove the plastic sheet. Satisfactory operation of
the viscous fan requires the air temperature to drop
20É F (11É C) or more. A definite decrease of audible-
fan-air-flow-noise should be noticed. Replace defec-
tive fan assemblies.
VISCOUS FAN DRIVE REPLACEMENT
REMOVAL
Some engines have the mechanical fan/viscous fan
drive assembly mounted directly to the water pump
hub (Fig. 38). It may also be mounted to a hub/bear-
ing attached to an aluminum bracket on the right
front side of engine (Fig. 39).
(1) Loosen but do not remove at this time, the four
fan hub mounting nuts (Figs. 38 or 39).
(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 as-
sembly.
Fig. 37 Viscous Fan DriveÐTypical
JCOOLING SYSTEM 7 - 27

(4) Remove four fan hub mounting nuts (Figs. 38
or 39) and remove fan/viscous fan drive assembly
from vehicle.
After removing fan blade/viscous fan drive assem-
bly,do notplace thermal viscous fan drive in hori-
zontal position. If stored horizontally, silicone fluid in
viscous fan drive could drain into its bearing assem-
bly and contaminate lubricant.INSTALLATION
(1) Assemble fan blade to viscous fan drive.
Tighten mounting bolts to 27 Nzm (20 ft. lbs.) torque.
(2) Position mounting flange of fan blade/viscous
fan drive assembly onto hub. Install four nuts and
tighten to 24 Nzm (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 ro-
tating in the wrong direction. Refer to appropriate
Engine Accessory Drive Belt Schematic in this
group for correct belt routing.
(3) Install accessory drive belts. Tension belts to
specifications. Refer to the Specifications section at
the end of this group.
FAN BLADE INSPECTION
The fan blades cannot be repaired. If the fan is
damaged, it must be replaced. Inspect the fan blades
as follows:
Lay fan blade assembly on a flat surface with lead-
ing edge facing 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.
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI-
FICATIONS.
Inspect fan assembly for cracks, bends, loose rivets
or broken welds. Replace fan if any damage is found.
CAUTION: If the fan blade assembly is replaced be-
cause of mechanical damage, the water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to ex-
cessive vibration.
AUXILIARY ELECTRIC COOLING FANÐXJ
MODELS WITH 4.0L ENGINE
OPERATION
XJ models equipped with a 4.0L engine may also
have an auxiliary electrical fan. This is with models
that have air conditioning and/or heavy duty cooling.
The fan is controlled by the cooling fan relay, which
is located in the Power Distribution Center (PDC).
For location of relay within the PDC (Fig. 40), refer
to label on PDC cover.
When coolant temperature is above 88ÉC (190ÉF),
the powertrain control module (PCM) grounds the re-
lay. Battery voltage is then applied to the fan
Fig. 38 Water Pump Mounted Cooling Fan
Fig. 39 Bracket Mounted Cooling Fan
7 - 28 COOLING SYSTEMJ