Chrysler Hemi 6 215, 245 & 265 Engine Overhaul Manual

7-0- 1 GROUP 7 - COOLING SYSTEM SECTION 0 - INDEX Section Page Subject Number Number INDEX 0 SERVICE DIAGNOSIS RADIATORS, PRESSURE CAPS, HOSES AND BELTS 2 Specifications 1 General Information 2 Radiator 2 Pressure Testing the Cooling System 2 Pressure Flushing the Cooling System 2 Radiator Cap 3 Radiator Hoses 3 Coolant Recovery System 4 Drive Belt Tensioning 4 WATER PUMPS, THERMOSTATS, FANS AND SHROUD 3 Specifications 1 Water Pump ("D" type engine) 2 Water Pump ("LA" type engine) 3 Thermostat 4 Fan 5 Thermal Control Fan Drive 5 Thermal Ignition Control (T.I.C.) Valve 6

SERVICE BULLETIN REFERENCE DATE NUMBER SUBJECT CHANGES I I

Condition EXTERNAL LEAKAGE INTERNAL LEAKAGE POOR CIRCULATION 7- 1 - 1 SECTION 1 - SERVICE DIAGNOSIS Possible Cause (a) Loose hose clamp. (b) Hose leaking. (c) Leaking radiator. (d) Worn or damaged water pump seal. (e) Loose core hole plug. (f) Damaged gasket, or dry gasket, if engine has been stored. (g) Cylinder head bolts loose, or tightened unevenly. (h) Leak at heater connection. (i) Leak at water temperature sending unit. (j) Leak at water pump attaching bolts. (k) Leak at exhaust manifold stud. (I) Crushed thermostat housing. (m) Dented radiator inlet or outlet tube. Correction (a) Replace the hose clamp. (b) Replace the hose. (c) Repair or replace the radiator as necessary. (d) Replace the water pump seal and impeller. (e) Install new core hole plug. (f) Replace gaskets as necessary. (g) Replace the cylinder head gasket and torque head in correct sequence. (h) Clean the heater connections and replace the hoses and clamps if necessary. (i) Tighten the water temperature sending unit. (j) Tighten the water pump attaching bolts to specifications. (k) Seal and re-drive the stud. (I) Replace the thermostat housing. (m) Straighten the radiator inlet or outlet tube as necessary. (n) Leaking heater core. (n) Repair or replace the heater core. (o) Cracked or porous water pump housing. (o) Replace the water pump assembly. (p) Warped or cracked cylinder head. (p) Replace the cylinder head. (q) Cracked cylinder block. (q) Replace the cylinder block. (r) Sand holes or porous condition in (r) Replace the cylinder block or block or head. cylinder head as necessary. (a) Faulty head gasket. (b) Refer to causes (f) to (j) listed under External Leakage. (c) Cylinder head cracked into valve compartment. (d) Cracked valve port. (e) Cylinder block cracked into push rod compartment. (f) Cracked cylinder wall. (a) Low coolant level. (b) Collapsed radiator hose. (A bottom hose with faulty spring may collapse only at high engine speeds). (c) Fan belt glazed, oil soaked, or loose. (d) Air leak through loose or faulty bottom hose. (e) Faulty thermostat. (f) Water pump impeller broken or loose on shaft. (a) Install a new head gasket. (b) Refer to corrections (f) to (j) listed under External Leakage. (c) Pressure test cooling system, replace the cylinder head. (d) Pressure test cooling system, replace the cylinder head. (e) Pressure test cooling system, replace the cylinder block. (f) Pressure test cooling system, replace the cylinder block. (a) Fill radiator to correct level. (b) Replace the hose and spring as necessary. (c) Tighten or replace the fan belt as necessary. (d) Replace the hose. (e) Replace the thermostat. (0 Replace the water pump internal parts.

Condition OVERHEATING OR APPARENT OVERHEATING (Refer to Causes Listed under "Poor Circulation") OVER FLOW LOSS CORROSION TEMPERATURE TOO LOW - SLOW ENGINE WARM UP WATER PUMP NOISY INSUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE BELT SQUEAL WHEN ACCELERATING ENGINE 7- 1-2 Possible Cause (g) Restricted radiator core water passages. (h) Restricted engine water jacket. (a) Low coolant level. (b) Blocked radiator air passages. (c) Incorrect ignition timing. (d) Low engine oil level. (e) Incorrect valve timing. (f) Inaccurate temperature gauge. (g) Restricted overflow tube. {h) Faulty radiator pressure cap or seat. (i) Frozen heat control valve. (j) Dragging brakes. (k) Excessive engine idling. (I) Frozen coolant. (a) Refer to causes listed under "Poor Circulation and Overheating." (b) Overfilling. (c) Coolant foaming due to insufficient corrosion inhibitor. (a) Leak at lower radiator hose. Correction (g) Flush the radiator thoroughly. (h) Flush the engine cooling system thoroughly. (a) Fill radiator to proper level. (b) Blow out the radiator passages. (c) Time the engine ignition system. (d) Add engine oil to the correct level. (e) Correct the engine valve timing. (f) Replace the temperature gauge. (g) Remove restriction from the overflow tube. (h) Replace the radiator cap and/ or seat. (i) Free up the manifold heat control valve. (j) Adjust the brakes. (k) Stop engine or increase idle R.P.M. (I) Thaw out cooling system, add anti- freeze as required. (a) Refer to corrections under "Poor Circulation and Overheating." (b) Adjust coolant to the correct level. (c) Flush the radiator and add anti-freeze or rust inhibitor as required. (a) Repair or replace corroded outlet fittings or corroded clamps. (b) Use of water containing large concen- (b) Use only clean soft water. tration of lime and minerals. (c) Insufficient corrosion inhibitor. (d) Use of anti-freeze for extended length of time. (a) Faulty thermostat. (b) Inaccurate temperature gauge. (a) Noisy seal. (b) Bearing rusted. (a) Belt too loose. (b) Belt excessive ly glazed or worn. (a) Belts too loose. (b) Belts glazed. (c) Use anti-freeze or rust inhibitor as required. (d) Drain cooling system and replace with new anti-freeze. (a) Replace the thermostat. (b) Replace the temperature gauge. (a) Add Water Pump Lube. (b) Replace bearing seal and impeller. (a) Adjust belt tension. (b) Replace and tighten as specified. (a) Adjust belt tension. (b) Replace belts.

7-2-1 SECTION 2 - RADIATORS, PRESSURE CAPS, HOSES & BELTS ...---------------SPECIFICATIONS --------------, Engine type .... 0 0. . .... .... 0 .. 0 Cooling System Capacity - with heater Radiator - type Core Size- 3o5 Litre - 4o0/4o3 Litre Pre 1/7/76 After 1/7/76 . -with air conditioning ... . . .. Pre 1/7/76 -502 Litre . 0 . .. .. oo .. - with air-conditioning or . H56 option - 5o9 Litre - with air-conditioning Fin Spacing Manual . . ... 0 0 .. . After 1 /7/7 6 Pre 1/ 7/76 After 1/7/7 6 Pre 1/ 7/76 After 1/7/ 76 -Automatic . .. .. Pre 1/7/76 After 1/7/76 -with air-conditioning .... Pre 1/7 !76 After 1/7/7 6 Auto-transmission oil cooler - Type -Location Radiator Pressure Cap 000 0 •ooo .o .. Radiator Pressure Setting .... 0 .. 0 .... . .. . Fan Belt Deflection - Alternator 0... . .. 0 - Power Steering .... - Air-conditioning "D" Type 1306 litres (24 pints) Fin and Tube 483 mm x 38 mm (19" X 1.5'') 559 mm x 32 mm (22" X 1.25") 660mm x 32mm (26" X 1.25") 559 mm x 38 mm (22" X lo5") . 660mm x 32mm (26" X 1.25") lOf/25 mm (1 ") 12f/25 mm (1 ") 11£/2 5 mm (1 ") 12f/25 mm (1 ") 13f/ 25 mm (1 ") Concentric Tube Radiator Bottom Tank Pressure Vent 110 kPa (16 pos.io) 10 mm (3/8") Smm (3/16") 13 mm (1/2") SPECIAL TOOLS E7C15 E7C20 Pressure testing gauge Flushing gun attachment "LA" Type 1408 Litres (26 pints) <--- 559 mm x 32 mm (22" X 1.25") 660mm x 32mm (26" X lo25") 559 mm x 51 mm (22" X 2") 660mm x 52mm (26" X 2") 559 mm x 38 mm (22" X 1.5") 559mm x 51 mm (22" X 2") <-- <- -- <-- - <--- <--- <--- <--- <--- <--- <- -- 11 mm (7 I 16")

7-2-2 GENERAL INFORMATION All engines are equipped with a thermostat as stan- dard equipment. With this thermostat, an ethyl-glycol base type anti-freeze may be used. In order to maintain cleanliness, the cooling system should be drained, thoroughly rinsed and filled with the correct coolant in accordance with the lubrication and maintenance schedule. Always discard old solutions removed. Maximum cleanliness can be assured by using a cooling system cleaner according to the directions on the label. If the system is badly rusted or clogged, it should be pressure flushed. When draining the cooling system, the block drain plugs should be removed and the radiator drain cock opened. Refill with demineralised water (or clean rain- water) adding Chrysler Parts Corrosion Inhibitor, also a compatible anti-freeze where required. The quantity of anti-freeze (if required) to be added should be sufficient to protect at the lowest anticipated temperature. RADIATOR Removal (I) Drain cooling system. (2) On vehicles with automatic transm1Ss1on, disconnect oil cooler lines at radiator bottom tank. (3) Remove upper and lower radiator hoses (using pliers E 1119). (4) Where equipped remove shroud attaching screws, separate shroud from radiator, position shroud rear- ward on engine for maximum clearance. (5) Remove radiator attaching screws. ( 6) Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal. Fan damage should always be avoided. Installation (I) Slide radiator down into position behind radiator support and install attaching screws. (2) Install fan shroud (if so equipped), connect hoses, and connect transmission oil cooler lines, if so equipped. (3) Fill cooling system to 25 mm (1 ") below filler neck seat with water and corrosion inhibitor as required. After warm-up, re-check coolant level. Main- tain at 25 mm (I") below filler neck. (4) On vehicles with automatic transmission measure transmission oil level after warm up and add oil as required. PRESSURE TESTING THE COOLING SYSTEM ( 1) For testing purposes only, fill radiator to within 13 mm (t") of filler neck. (2) Wipe filler neck sealing surface clean. (3) Attach Tool E7Cl5 to filler neck and apply 120 kPa or 17 p.s.i. pressure (Fig. 1). (4) If pressure gauge reading holds steady, the system is satisfactory. If pressure drops, continue test as follows: (5) Check all points for external leaks. If no external leaks are found after the gauge dial showed a drop in pressure, continue test. (6) Remove tester and run engine until normal operating temperature is reached. (7) Re-attach Tool E7C15, apply 48 kPa (7 p,s.i.) pressure and increase engine speed to half throttle. (8) If needle on dial fluctuates, it indicates a com- bustion leak, generally at the head gasket. (9) If needle on dial did not fluctuate in step (7), sharply accelerate the engine several times. If an abnormal amount of water emits from the tail pipe, it indicates a head gasket leak, cracked block or cracked head. Fig. !-Pressure testing cooling system (Tool E7Cl5) PRESSURE FLUSHING THE COOLING SYSTEM KPl.OA (I) Clean the system, using a cooling system cleaner according to the directions on the label. (2) Drain the radiator and remove both radiator hoses. (3) Remove the thermostat and re-install the housing.

7-2-3 (4) Connect flushing gun, Tool E7C20, to the engine thermostat housing, using a length of rubber hose. (5) Install a drain hose in the water pump inlet. (6) Connect a flushing gun to sources of water and air pressure. (7) Fill the block with water by restricting the drain hose. Leave the water valve open. (8) Open and close the air valve to agitate and force away any foreign material. Continue the operation until the water runs clear. (9) For final block flushing, fill the block with water and remove the drain plugs. Using air pressure until the water from the block drains runs clear. (10) To pressure flush the radiator, disconnect the two hoses from the engine and attach them to the radiator. Attach the flushing gun hose to the lower radiator tank and the drain hose to the top tank. (11) Fill the radiator with water, leave the water valve open, and open and close the air valve until the water runs clear. (12) For final radiator flushing, attach flushing gun to top hose and repeat flushing operation. (13) Test the thermostat (see Section 3). If satisfactory, install with pellet toward engine, using a new gasket. (14) Install hoses and refill cooling system to 25 mm ( 1 ") below filler neck, using demineralised (or rain) water and adding Chrysler Parts Corrosion Inhibitor also a compatible anti-freeze, where required. (15) Run engine until the temperature gauge indicates normal operating temperature and continue an additional five minutes to release any air trapped in system. Check coolant level and, if necessary, add additional water. RADIATOR CAP This cap is the pressure-sealing type. Its putpose is to hold .the cooling system under a slight pressure, in- creasing the boiling point of the cooling solution and preventing loss of solution due to evaporation and over- Fig. 2-Radiator pressure caps The cap (Fig. 2) has spring-loaded valve, the seat of which is below the overflow pipe in the filler neck. This prevents the escape of air or liquid while the cap is in position. When the cooling system pressure reaches a pre-determined point, the cap valve opens and will again close when the pressure drops below the pre- determined point. When removing the pressure type cap from the radiator, perform the operation in two steps. Loosening the cap to its first notch raises the valve from the gasket and releases the pressure through overflow pipe. In the first stage position of the cap it should be possible to depress the cap approximately 3mm (1/8"). The prongs on the cap can be bent to adjust this condition. Care must be taken that the cap is not too loose as this would prevent proper sealing. CAUTION: When removing the cap, loosen it slowly and then pause a moment. This will avoid possible burning by hot water or steam. Continue to turn the cap to the left until it can be removed. Fig. 3- Testing the pressure cap (Tool E7Cl5) Pressure Testing the Radiator Cap (1) Attach neoprene seal and adaptor to tester E7C15 (See Fig. 3). (2) Dip the pressure cap in water and apply cap to tester adaptor. (3) Apply pressure to cap. If pressure cap fails to hold pressure up to the specified pressure of the cap, replace the cap. RADIATOR HOSES The hoses are removed and installed using hose clamp pliers E1119. A hardened, cracked, or swollen hose should be replaced. The spring inside the lower hose is necessary to prevent collapsing of the hose due to suction at high engine speeds. If this spring is weak or broken, it should be replaced.

7-2-4 COOLANT RECOVERY SYSTEM Vehicles equipped with this system have a translucent plastic reservoir with a connecting tube to the radiator filler neck and a special pressure cap. The plastic reservoir has a filler opening with a plastic "screw-on" type cap and an overflow tube open to the atmosphere. With this system the radiator is normally completely full. When heated coolant in the engine expands and is forced out of the radiator and overflows into the reservoir. When the engine cools down the coolant contracts and vacuum draws coolant from the reservoir back into the radiator thus keeping it full. Testing Coolant Recovery System With coolant in the reservoir at the proper level and the radiator cap installed, remove the radiator drain plug. · coolant should be drawn from the reservoir into the radiator. Do not leave drain plug out too long as this could allow air to enter the system. If test does not draw coolant from the reservoir, check for leaks at the radiator filler and overflow nipple, radiator cap and reservoir tube. It may be necessary to pressure test the radiator cap and cooling system to locate a leak. DRIVE BELT TENSIONING To correctly adjust the alternator or generator drive belt the following procedure should be adhered to: (I) Loosen the alternator mounting bolts and with the aid of a lever apply tension to the drive belt being careful not to damage the alternator. (2) Tighten the mounting bolts and check the belt deflection as follows: DUAL BEL TS-COMP . & ALT. DRIVE BELT- FAN & P/S PUMP OR IDLER DRIVE Fig. 4- Coolant recovery system Apply a 4.5 kg (10 lb.) pull to the centre of the longest run of the belt. A small spring scale can be used to determine the 4.5 kg (I 0 lb.) pull. The belt deflection at the point of pull should be set to specifications. NOTE: Any belt that bas been replaced must be checked and re-adjusted after stretching. Any belt that bas been operated for a minimum of half an hour is considered to be used. The twin drive belts used on heavy duty engines are a matched pair and should replacement become necessary both belts must be replaced. Fig. 5-8 cylinder models belt deflection locations, including power steering, and/or air conditioning where equipped

Hemi-6 cylinder models with air cond. and power steering 7-2-5 Hemi-6 cylinder models with power steering only. Fig. 6-6 cylinder belt deflection locations Fig. 7-6 cylinder fan, air conditioning and power steering drive belt layout

7-2-6 I ~~/~ ' '\.~WER STG ~MP ASSY ' -~ ~.a Nm 130 lbo. t~) PUMP DRIVE PULLEY ~ 23 Nm (2110 lbo. lno) Fig. 8-6 cylinder fan and power steering drive belt layout DUAL BELTS-COMP. & ALT. DRIVE WASHER (6) ACCESSORY DRIVE PULLEY AR~ANGEMENT (9 Fig. 9- 8 cylinder accessory drive belt layout (9 23 Nm (~ lba. ln.)

Chrysler Hemi 6 215, 245 & 265 Engine Overhaul Manual

You're Reading a Preview

Recently Viewed