2001 DODGE RAM Service Repair Manual

gas type warning lights homelink radio antenna air filter reset

Load previous 8 pages

Page 385 of 2889

DODGE RAM 2001 Service Repair Manual (4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL) (Fig. 17).
(5) Remove two generator mounting bolts. Do not
remove any wiring at generator. If equipped with

Page 386 of 2889

DODGE RAM 2001 Service Repair Manual (4) Position thermostat housing to intake manifold.
Note the word FRONT stamped on housing (Fig. 20).
For adequate clearance, thismustbe placed towards
front of vehicle. The housing is slightly angled

Page 387 of 2889

DODGE RAM 2001 Service Repair Manual ENGINE COOLANT
THERMOSTAT - 8.0L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on all gas powered engines is
located beneath the

ENGINE COOLANT
THERMOSTAT - 8.0L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on all gas powered engines is
located beneath the thermostat housing at the front
of the intake manifold (Fig. 22).
The thermostat is a moveable sleeve type.
Coolant leakage into the pellet container will cause
the thermostat to fail in the open position. Thermo-
stats very rarely stick. Do not attempt to free a ther-
mostat with a prying device.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance,
increased exhaust emissions and crankcase condensa-
tion that can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTINGÐTHERMOSTAT
ON-BOARD DIAGNOSTICS
Allgasoline powered modelsare equipped with
On-Board Diagnostics for certain cooling system com-
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor-
mation. If the powertrain control module (PCM)
detects low engine coolant temperature, it will record
a Diagnostic Trouble Code (DTC) in the PCM mem-
ory. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or by poor
heater performance unless a DTC is present. Refer to
the Diagnosis section of this group for other probable
causes. For other DTC numbers, (Refer to 25 - EMIS-
SIONS CONTROL - DESCRIPTION).
The DTC can also be accessed through the DRB
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures information for diagnostic informa-
tion and operation of the DRB scan tool.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
A rubber lip-type seal with a metal shoulder is
pressed into the intake manifold beneath the thermo-
stat (Fig. 23).
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
Fig. 22 ThermostatÐ8.0L V-10 Engine
1 - COOLANT TEMP. SENSOR (FOR PCM)
2 - HEATER SUPPLY FITTING
3 - BOLTS (6)
4 - HOUSING WITH INTEGRAL SEAL
5 - THERMOSTAT
6 - RUBBER LIP SEAL
7 - TEMP. GAUGE SENDING UNIT
7 - 52 ENGINEBR/BE

Page 388 of 2889

DODGE RAM 2001 Service Repair Manual (3) Remove the two support rod mounting bolts
and remove support rod (intake manifold-to-genera-
tor mount) (Fig. 24).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN

Page 389 of 2889

DODGE RAM 2001 Service Repair Manual cial Seal Tool number C-3995-A with handle tool
number C-4171.
(4) Install thermostat into recessed machined
groove on intake manifold (Fig. 25).
(5) Install thermostat housing (Fig. 25).
(6) Install

cial Seal Tool number C-3995-A with handle tool
number C-4171.
(4) Install thermostat into recessed machined
groove on intake manifold (Fig. 25).
(5) Install thermostat housing (Fig. 25).
(6) Install housing-to-intake manifold bolts.
Tighten bolts to 25 N´m (220 in. lbs.) torque.
CAUTION: Housing bolts should be tightened
evenly to prevent damage to housing and to pre-
vent leaks.
(7) Connect the wiring to both sensors.
(8) Install the upper radiator hose and hose clamp
to thermostat housing.
(9) Install support rod.
(10) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(11) Connect negative battery cable to battery.
(12) Start and warm engine. Check for leaks.
ENGINE COOLANT
THERMOSTAT - 5.9L DIESEL
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing. An engine
with the thermostat removed will operate in the
radiator bypass mode, causing an overheat condi-
tion.
The thermostat of the 5.9L diesel engine is located
in the front of the cylinder head, underneath the
water outlet connector (Fig. 26).
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine
warmup time, unreliable warmup performance,
increased exhaust emissions and crankcase condensa-
tion that can result in sludge formation.
OPERATION
The wax pellet is located in a sealed container at
the spring end of the thermostat. When heated, the
pellet expands, overcoming closing spring tension
and water pump pressure to force the valve to open.
DIAGNOSIS AND TESTINGÐTHERMOSTAT
The cooling system used with the diesel engine
provides the extra coolant capacity and extra cooling
protection needed for higher GVWR (Gross Vehicle
Weight Rating) and GCWR (Gross Combined Weight
Rating) vehicles.This system capacity will not effect warm up or
cold weather operating characteristics if the thermo-
stat is operating properly. This is because coolant
will be held in the engine until it reaches the ther-
mostat ªsetº temperature.
Diesel engines, due to their inherent efficiency are
slower to warm up than gasoline powered engines,
and will operate at lower temperatures when the
vehicle is unloaded. Because of this, lower tempera-
ture gauge readings for diesel versus gasoline
engines may, at times be normal.
Typically, complaints of low engine coolant temper-
ature are observed as low heater output when com-
bined with cool or cold outside temperatures.
To help promote faster engine warm-up, the elec-
tric engine block heater must be used with cool or
cold outside temperatures. This will help keep the
engine coolant warm when the vehicle is parked. Use
the block heater if the outside temperature is below
4ÉC (40ÉF).Do not use the block heater if the
outside temperature is above 4ÉC (40ÉF).
A ªCold Weather Coverº is available from the parts
department through the Mopar Accessories product
line. This accessory cover is designed to block airflow
entering the radiator and engine compartment to
promote faster engine warm-up. It attaches to the
front of the vehicle at the grill opening.The cover is
Fig. 26 ThermostatÐ5.9L DieselÐTypical
1 - WATER OUTLET CONNECTOR
2 - THERMOSTAT HOUSING
3 - THERMOSTAT
7 - 54 ENGINEBR/BE
ENGINE COOLANT THERMOSTAT - 8.0L (Continued)

Page 390 of 2889

DODGE RAM 2001 Service Repair Manual to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result.Refer to the litera-
ture supplied with the cover for additional informa-
tio

to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result.Refer to the litera-
ture supplied with the cover for additional informa-
tion.
(1) To determine if the thermostat is defective, it
must be removed from the vehicle (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT THERMO-
STAT - REMOVAL).
(2) After the thermostat has been removed, exam-
ine the thermostat and inside of thermostat housing
for contaminants. If contaminants are found, the
thermostat may already be in a ªstuck openº position.
Flush the cooling system before replacing thermostat
(Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(3) Place the thermostat into a container filled
with water.
(4) Place the container on a hot plate or other suit-
able heating device.
(5) Place a commercially available radiator ther-
mometer into the water.
(6) Apply heat to the water while observing the
thermostat and thermometer.
(7) When the water temperature reaches 83ÉC
(181ÉF) the thermostat should start to open (valve
will start to move). If the valve starts to move before
this temperature is reached, it is opening too early.
Replace thermostat. The thermostat should be fully
open (valve will stop moving) at 95ÉC (203ÉF). If the
valve is still moving when the water temperature
reaches 203É, it is opening too late. Replace thermo-
stat. If the valve refuses to move at any time, replace
thermostat.
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Disconnect the battery negative cables.
(2) Drain cooling system until coolant level is
below thermostat (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
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). SNAP-ON CLAMP TOOL (NUMBER HPC-20)
MAY BE USED FOR LARGER CLAMPS. ALWAYSWEAR SAFETY GLASSES WHEN SERVICING CON-
STANT 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 a matching number or letter.
(3) Remove radiator hose clamp and hose from
thermostat housing.
(4) Remove the three (3) water outlet-to-cylinder
head bolts and remove the water outlet connector
(Fig. 27).
(5) Clean the mating surfaces of the water outlet
connector and clean the thermostat seat groove at
the top of the thermostat housing (Fig. 27).
INSTALLATION
(1) Install the thermostat into the groove in the
top of the thermostat housing (Fig. 27).
(2) Install the water outlet connector and bolts.
Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(3) Install the radiator upper hose and clamp.
(4) Fill the cooling system with coolant (Refer to 7
- COOLING - STANDARD PROCEDURE).
(5) Connect the battery negative cables.
(6) Start the engine and check for coolant leaks.
Run engine to check for proper thermostat operation.
Fig. 27 Thermostat Removal/Installation
1 - WATER OUTLET CONNECTOR
2 - THERMOSTAT HOUSING
3 - THERMOSTAT
BR/BEENGINE 7 - 55
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)

Page 391 of 2889

DODGE RAM 2001 Service Repair Manual FAN DRIVE VISCOUS CLUTCH
- 3.9L/5.2L/5.9L/8.0L
DESCRIPTION
The thermal viscous fan drive (Fig. 28) is a sili-
cone-fluid- filled coupling used to connect the fan
blades to the water pump shaft. The co

FAN DRIVE VISCOUS CLUTCH
- 3.9L/5.2L/5.9L/8.0L
DESCRIPTION
The thermal viscous fan drive (Fig. 28) is a sili-
cone-fluid- filled coupling used to connect the fan
blades to the water pump shaft. The coupling allows
the fan to be driven in a normal manner. This is
done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
OPERATION
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit (a typical
viscous unit is shown in (Fig. 29). This spring coil
reacts to the temperature of the radiator discharge
air. It engages 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 necessary, the fan will remain at a reduced rpm
regardless 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 to 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
reacts and the fan speed is reduced to the previous
disengaged speed.
DIAGNOSIS AND TESTINGÐVISCOUS FAN
DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
²The underhood temperature is above the engage-
ment point for the viscous drive coupling. This may
occur when ambient (outside air temperature) is very
high.
²Engine loads and temperatures are high such as
when towing a trailer.
²Cool silicone fluid within the fan drive unit is
being redistributed back to its normal disengaged
(warm) position. This can occur during the first 15
seconds to one minute after engine start-up on a cold
engine.
LEAKS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears
excessive, replace the fan drive unit.
VISCOUS DRIVE
If the fan assembly free-wheels without drag (the
fan blades will revolve more than five turns when
spun by hand), replace the fan drive. This spin test
must be performed when the engine is cool.
For the following test, the cooling system must be
in good condition. It also will ensure against exces-
sively high coolant temperature.
Fig. 28 Viscous Fan
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
Fig. 29 Viscous Fan DriveÐTypical
1 - VISCOUS FAN DRIVE
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
7 - 56 ENGINEBR/BE

Page 392 of 2889

DODGE RAM 2001 Service Repair Manual WARNING: 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 inc

WARNING: 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. The timing light is to be used as a
strobe light. This step cannot be used on the diesel
engine.
(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
DIRECT 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.
Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 88É C (190É F).
Fan driveengagementshould start to occur at/be-
tween:
²3.9L/5.2L/5.9L gas engines Ð 79É C (175É F)
²8.0L engine Ð 88É to 96É C (190É to 205É F)
²5.9L diesel engine Ð 71É to 82É C (160É to 179É
F)Engagement is distinguishable by a definite
increasein fan flow noise (roaring). The timing light
also will indicate an increase in the speed of the fan
(non-diesel only).
(7) When viscous drive engagement is verified,
remove the plastic sheet. Fan drivedisengagement
should start to occur at between 57É to 79É C (135É to
175É F). A definitedecreaseof fan flow noise (roar-
ing) should be noticed. If not, replace the defective
viscous fan drive unit.
CAUTION: Some 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 overheating.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatiguecracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
FAN DRIVE VISCOUS CLUTCH
- 5.9L DIESEL
DESCRIPTION
The thermal viscous fan drive (Fig. 30) is a sili-
cone-fluid- filled coupling used to connect the fan
blades to the water pump shaft. The coupling allows
the fan to be driven in a normal manner. This is
done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
OPERATION
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit (a typical
viscous unit is shown in (Fig. 31). This spring coil
reacts to the temperature of the radiator discharge
air. It engages 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 necessary, the fan will remain at a reduced rpm
regardless of engine speed.
Fig. 30 Viscous Fan
1 - THREADED SHAFT
2 - BOLT (4)
3 - FAN BLADE
4 - THREADED NUT
5 - VISCOUS FAN DRIVE
BR/BEENGINE 7 - 57
FAN DRIVE VISCOUS CLUTCH - 3.9L/5.2L/5.9L/8.0L (Continued)

Load next 8 pages

Page: < prev 1-10 ... 353-360 361-368 369-376 377-384 385-392 393-400 401-408 409-416 417-424 ... 2896 next >

high beam bluetooth battery location air filter warning fuse chart