Repair Procedure: Overview

This bulletin involves making modifications to the heater supply hose and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes).

NOTE:
IF TSB 18-09-98 REV. B. HAS BEEN PERFORMED, THE INFORMATION IN THIS BULLETIN WILL NOT APPLY. FURTHER DIAGNOSIS AND TESTING WILL BE REQUIRED.

WARNING:
DO NOT REMOVE THE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM HOT COOLANT CAN OCCUR.

1. If the heater supply hose is configured as shown in Figure 1 "A", obtain heater supply hose p/n 04596346AA, heater supply hose p/n 04767170AB, four hose clamps p/n 06502018 and two hose clamps p/n 04592126. If the heater supply hose is configured as shown in Figure 1 "B", obtain heater supply hose p/n 04767170AB, four hose clamps p/n 06502018 and two hose clamps p/n 04592126.

2. For configuration "A" (Figure 1), remove and discard the existing heater supply hose.

3. For configuration "A", remove the quick connector from heater supply hose p/n 04596346AA and install it onto the heater supply tube coming out of the back of the engine.



NOTE:
POSITION THE QUICK CONNECT SO THE HOLES FACE UP/DOWN AND THE FLATS FACE LEFT/RIGHT.

4. For configuration "B" (Figure 1), leave the quick connect attached to the heater supply tube and remove and discard the rest of the supply hose assembly.





5. For both configurations, cut the new hose p/n 04767170AB as shown in Figure 2.

6. For both configurations, insert the Tee into the cut section of the heater hose. Use two hose clamps p/n 06502018 to complete the assembly. Before tightening the clamps, position the Tee to the 2:00 0-Clock position as viewed from the front of the vehicle (Figure 2).

7. Install one end of the 3/8 inch hose onto the Tee using hose clamp p/n 04592126.

8. Install the heater hose onto the heater supply tube and heater core. Use clamps p/n 06502018 to secure both ends.





9. Install the remaining end of the 3/8 inch hose to the coolant pressure bottle. Use clamp p/n 04592126. The final heater hose configuration is shown in Figure 3.

10. Use MOPAR antifreeze 5 year/100,000 mile formula p/n 05011764AB and follow all cooling system fill procedures listed in the service manual.

NOTE:
COOLING SYSTEM FILL PROCEDURES ARE CRITICAL TO THE OVERALL COOLING SYSTEM PERFORMANCE.

11. Operate the engine at 2000 to 2300 RPM for 20 minutes. This will remove any remaining air from the cooling system. The DRB III(R) can be used to set the engine RPM within engine actuators, RPM set. Periodic monitoring of this feature is necessary since the actuator test will time out in 5 minutes. The reset feature can be used to continue the engine RPM actuator feature.

NOTE:
DO NOT EXCEED 2500 RPM DURING THE AIR PURGE PROCEDURE.