1996 CHRYSLER VOYAGER belt

DESCRIPTION AND OPERATION
WATER PIPESÐ3.0L ENGINE
The 3.0L engine uses metal piping beyond the
lower radiator hose to route (suction) coolant to the
water pump, which is located in the V of the cylinder
banks (Fig. 10).
These pipes are provided with inlet nipples for
thermostat bypass and heater return coolant hoses,
and brackets for rigid engine attachment. The pipes
employ O-rings for sealing at their interconnection
and to the water pump (Fig. 10).
COOLANT PERFORMANCE
Performance is measurable. For heat transfer pure
water excels (Formula = 1 btu per minute for each
degree of temperature rise for each pound of water).
This formula is altered when necessary additives to
control boiling, freezing, and corrosion are added as
follows:
²Pure Water (1 btu) boils at 100ÉC (212ÉF) and
freezes at 0ÉC (32ÉF)
²100 percent Glycol (.7 btu) can cause a hot
engine and detonation and will lower the freeze point
to -22ÉC (-8ÉF).
²50/50 Glycol and Water (.82 btu) is the recom-
mended combination that provides a freeze point of
-37ÉC (-35ÉF). The radiator, water pump, engine
water jacket, radiator pressure cap, thermostat, tem-
perature gauge, sending unit and heater are all
designed for 50/50 glycol.CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended.
Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of -59ÉC
(-50ÉF).
CAUTION: Richer mixtures cannot be measured
with field equipment. This can lead to problems
associated with 100 percent glycol.
RADIATOR HOSES AND CLAMPS
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A
SHOP TOWEL OVER THE CAP AND WITHOUT
PUSHING DOWN ROTATE IT COUNTERCLOCKWISE
TO THE FIRST STOP. ALLOW FLUIDS AND STEAM
TO ESCAPE THROUGH THE OVERFLOW TUBE.
THIS WILL RELIEVE SYSTEM PRESSURE
The hoses are removed by using constant tension
clamp pliers to compress the hose clamp.
A hardened, cracked, swollen or restricted hose
should be replaced. Do not damage radiator inlet and
outlet when loosening hoses.
Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended.
Spring type hose clamps are used in all applica-
tions. If replacement is necessary replace with the
original MOPARtequipment spring type clamp.
WATER PUMPÐ2.4L ENGINE
The water pump has a diecast aluminum body and
housing with a stamped steel impeller. The water
pump bolts directly to the block. Cylinder block to
water pump sealing is provided by a rubber O-ring.
The water pump is driven by the timing belt. Refer
to Timing Belt in Group 9, Engine for component
removal providing access to water pump.
WATER PUMPÐ3.0L ENGINE
The pump bolts directly to the engine block, using
a gasket for pump to block sealing (Fig. 11). The
pump is serviced as a unit.
The water pump is driven by the timing belt. See
Timing Belt in Group 9, Engine for component
removal providing access to water pump.
Fig. 10 Engine Inlet Coolant Pipes 3.0L Engine
7 - 6 COOLING SYSTEMNS

WATER PUMPÐ3.3/3.8L ENGINES
The pump has a die cast aluminum body and a
stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring for sealing. It is driven by
the back surface of the Poly-V Drive Belt.
DIAGNOSIS AND TESTING
Fig. 11 Water PumpÐ3.0L Engine
ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. Adjust belt tension (4 cyl. engine).
Replace belt (6 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. Adjust belt tension (4 cyl. engine).
Replace belt (6 cyl. engine)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE1. Belts too loose 1. Adjust belt tension (4 cyl. engine).
Replace belt (6 cyl. engine)
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley5. Replace pulley
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. Adjust belt tension (4 cyl. engine).
Replace belt (6 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
NSCOOLING SYSTEM 7 - 7
DESCRIPTION AND OPERATION (Continued)

Continue filling system until full, this provides bet-
ter heater performance.Be careful not to spill
coolant on drive belts or the generator.
Fill coolant reserve system to at least the MAX
mark with 50/50 solution. It may be necessary to add
coolant to the reserve tank after three or four warm
up/cool down cycles to maintain coolant level between
the MAX and MIN mark. This will allow trapped air
to be removed from the system.
REMOVAL AND INSTALLATION
WATER PUMPÐ2.4L ENGINE
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on a hoist. Remove right inner
splash shield.
(3) Remove accessory drive belts. Refer to Acces-
sory Drive Belt service in this section.
(4) Drain cooling system. Refer to Cooling System
Draining in this section.
(5) Support engine from the bottom and remove
right engine mount.
(6) Remove right engine mount bracket.
(7) Remove timing belt. Refer to Group 9, Engine
for procedure.
(8) Remove timing belt idler pulley.
(9) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(10) Remove rear timing belt cover.
(11) Remove water pump attaching screws to
engine (Fig. 16).
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 17).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may cause damage to the
O-ring and cause a coolant leak.(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.) (Fig. 16). Pressurize
cooling system to 15 psi with pressure tester and
check water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install rear timing belt cover.
(5) Install camshaft sprockets and torque bolts to
101 N´m (75 ft. lbs.).
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(7) Install timing belt. Refer to Group 9, Engine,
2.4L Timing Belt.
(8) Install right engine mount bracket and engine
mount. Refer to Group 9 for procedure.
(9) Fill cooling system. SeeCooling System Fill-
ing.
(10) Install accessory drive belts, Refer to Acces-
sory Drive Belts, in this section.
(11) Lower vehicle and connect battery cable.
WATER PUMP INLET TUBEÐ2.4L ENGINE
REMOVAL
(1) Drain cooling system. Refer to procedure out-
lined in this section.
(2) Remove upper radiator hose to access the hose
connections at the inlet tube.
(3) Remove lower radiator hose and heater hose
from the inlet tube (Fig. 18).
(4) Remove the 2 fasteners that hold the inlet
tube to the block.
(5) Rotate tube while removing the tube from the
engine block (Fig. 19).
INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 19).
(2) Lube O-ring with coolant and install into the
cylinder block opening.
(3) Install 2 fasteners and tighten to 12 N´m (105
in. lbs.).
(4) Connect lower radiator hose and heater hose
to inlet tube (Fig. 18).
Fig. 16 Water PumpÐ2.4L Engine
Fig. 17 Water Pump Body
NSCOOLING SYSTEM 7 - 17
SERVICE PROCEDURES (Continued)

(5) Install upper radiator hose.
(6) Fill cooling system. Refer to procedure outlined
in this section.
WATER PUMPÐ3.0L ENGINE
REMOVAL
(1) Drain cooling system. Refer to Draining Cool-
ing System in this group.
(2) To gain access to water pump refer to Group 9,
Engine for Timing Belt Removal.
(3) Remove mounting bolts.
(4) Separate pump from water inlet pipe (Fig. 20)
and (Fig. 21) and remove.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks, if the shaft seal is leaking, evi-
dent by traces of coolant leaks from vent holeAin
(Fig. 21).(3) Impeller rubs the inside of pump.
(4) Loose or rough turning bearing.
Fig. 18 Water Pump Inlet Tube Hose Connections
Fig. 19 Water Pump Inlet Tube ÐService
Fig. 20 Water PumpÐ3.0L Engine
Fig. 21 Water Pump Inspection
Fig. 22 Water Pipe O-Ring
7 - 18 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Clean all gasket and O-ring surfaces on pump
and water pipe inlet tube.
(2) Install new O-ring on water inlet pipe (Fig.
22). Wet the O-ring (with water) to ease assembly.
CAUTION: Keep the O-ring free of oil or grease.
(3) Install new gasket on water pump and install
pump inlet opening over water pipe, press assembly
to cause water pipe insertion into pump housing.
(4) Install pump to block mounting bolts and
tighten to 27 N´m (20 ft. lbs.).
(5) See Timing Belt in Engine, Group 9 and
install timing belt. Reassemble engine.
(6) Fill cooling system. See Refilling Cooling Sys-
tem.
WATER PUMPÐ3.3/3.8L ENGINES
REMOVAL
(1) Drain Cooling System. Refer to Draining Cool-
ing System in this group.
(2) Remove Poly-V Drive Belt.
(3) Remove right front lower fender shield.
(4) Remove pump pulley bolts and remove pulley.
(5) Remove pump mounting screws (Fig. 23).
Remove water pump.
(6) Remove and discard O-ring seal.
(7) Clean O-ring groove and O-ring surfaces on
pump and chain case cover. Take care not to scratch
or gouge sealing surface.
INSTALLATION
(1) Install new O-ring into groove (Fig. 24).
(2) Install pump to chain case cover. Torque
screws to 12 N´m (105 in. lbs.)
(3) Rotate pump by hand to check for freedom of
movement.(4) Position pulley on pump. Install screws and
torque to 30 N´m (250 in. lbs.).
(5) Install drive belt. See Accessory Drive Belts in
this group.
(6) Install right front lower fender shield.
(7) Refill Cooling System. See Refilling Cooling
System.
THERMOSTATÐ2.4L ENGINE
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
group.
(2) Remove thermostat housing bolts and housing
(Fig. 25).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
Fig. 23 Water Pump Ð3.3/3.8L Engines
Fig. 24 Water Pump Body
Fig. 25 Thermostat, Housing, and Outlet
ConnectorÐ2.4L Engine
NSCOOLING SYSTEM 7 - 19
REMOVAL AND INSTALLATION (Continued)

(13) Raise the vehicle. Install the lower auxiliary
transmission cooler lines to the retaining clips on the
fan module shroud, if equipped.
(14) Install outlet hose retainer clip to the shroud.
Install the radiator outlet hose to the retaining clip.
(15) Lower the vehicle.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and
Refill of this section for procedure.
(2) Remove power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
(5) Install power cord plug to heater.
ACCESSORY DRIVE BELTSÐ2.4L
REMOVAL/INSTALLATION-ADJUST
GENERATOR AND AIR CONDITIONING
(1) Loosen lower generator pivot bolt and upper
locking nut, then loosen adjusting bolt (Fig. 32) to
remove belt tension.
CAUTION: Belt damage may occur if the following
procedure is not performed.
(2) Tighten lock nut to 21 N´m (180 in. lbs.) and
torque generator pivot bolt to 54 N´m (40 ft. lbs.). To
assure proper alignment of generator assembly.
Adjust belt tension by tightening the adjusting bolt
until proper belt tension is obtained. Refer to tension
specification in Belt Tension Chart.
(3) Torque lock nut to 54 N´m (40 ft. lbs.).
POWER STEERING PUMP
(1) From on top of the vehicle loosen locking nuts
D and F (Fig. 33).
(2) From under the vehicle loosen the pivot bolt E.
Loosen adjusting bolt G until belt can be removed.
(3) After installing a new belt, adjust belt tension
by tightening the adjusting bolt until the proper ten-sion obtained. Refer to tension specification in Belt
Tension Chart.
(4) Tighten locking nuts D and F to 54 N´m (40 ft.
lbs.).
(5) Tighten pivot bolt E to 54 N´m (40 ft. lbs.)
Fig. 32 Air Conditioning Compressor/Generator
BeltsÐ2.4L
Fig. 33 Power Steering Pump Adjustment
NSCOOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)

ACCESSORY DRIVE BELTSÐ3.0L
GENERATOR/POWER STEERING PUMP BELT
REMOVAL/INSTALLATION
The Poly-V generator/power steering pump belt is
provided with a dynamic tensioner (Fig. 34) to main-
tain proper belt tension. To remove or install this
belt, apply force in a clockwise direction to the ten-
sioner pulley bolt (Fig. 34).
AIR CONDITIONING BELT
REMOVAL
To remove the air conditioning compressor drive
belt, first loosen the idler pulley lock nut, then turn
the adjusting screw to lower the idler pulley (Fig.
35).
INSTALLATION/ADJUSTMENT
To adjust the air conditioning drive belt,
loosen the idler pulley lock nut (Fig. 35) and adjust
belt tension by tightening adjusting screw. Refer toProper Belt Tension and Belt Tension Chart in this
Section for procedure. Tighten pulley lock nut to 54
N´m (40 ft. lbs.) after adjustment.
ACCESSORY DRIVE BELTÐ3.3/3.8L
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING
COMPRESSOR AND WATER PUMP DRIVE BELT
The Poly-V Drive belt is provided with a dynamic
tensioner (Fig. 36) to maintain proper belt tension.
To remove or install this belt.
(1) Raise vehicle on hoist.
(2) Remove right front splash shield.
(3) Release tension by rotating the tensioner
clockwise (Fig. 36).
(4) Reverse above procedure to install.
CLEANING AND INSPECTION
WATER PUMP
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; if the seal is leaking, this will be
evident by traces of thick deposits of greenish-brown
dried glycol running down the pump body and com-
ponents below. A thin black stain below pump weep
hole is considered normal operation.
(3) Impeller rubs inside of chain case cover
3.3/3.8L or cylinder block 2.4L engines.
(4) Excessively loose or rough turning bearing.
Fig. 34 Release Belt TensionerÐ3.0L
Fig. 35 Air Conditioning Drive BeltÐ3.0L Engine
Fig. 36 Accessory Drive BeltÐ3.3/3.8L Engines
7 - 24 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

NOTE: It is normal for the water pump to weep a
small amount of coolant from the weep hole (black
stain on water pump body). Do not replace the
water pump if this condition exists. Replace the
water pump if a heavy deposit or a steady flow of
green/brown engine coolant is evident on water
pump body from the weep hole (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
ACCESSORY DRIVE BELT
When inspecting serpentine drive belts, small
cracks that run across the ribbed surface of the belt
from rib to rib (Fig. 37), are considered normal. these
are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal.
Any belt with cracks running along the rib must be
replaced (Fig. 37). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
RADIATOR PRESSURE CAP
INSPECTION
Hold the cap in hand,right side up. The vent
valve at the bottom of the cap should open. If the
rubber gasket has swollen and prevents the valve
from opening, replace the cap.
Hold the cleaned cap in handupside down.If any
light shows between vent valve and rubber gasket,
replace cap.Do not use a replacement cap that
has a spring to hold the vent shut.
Replacement cap must be of the type designed for
coolant reserve system with a completely sealed dia-
phragm spring, and rubber gasket to seal to fillerneck top surface. This design assures coolant return
to radiator.
COOLING SYSTEM CLEANING
Drain cooling system (see:Cooling System
Draining) and refill with clean water (see:Cooling
System Refilling). Run engine with radiator cap
installed until upper radiator hose is hot. Stop
engine and drain water from system. If water is
dirty; fill, run, and drain system again, until water
runs clear.
REVERSE FLUSHING THE RADIATOR
Drain cooling system and remove radiator hoses
from engine. Install suitable flushing gun in radiator
lower hose. Fill radiator with clean water and turn
on air in short blasts.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedure until water runs
clear.
REVERSE FLUSHING THE ENGINE
Drain radiator (see:Draining Cooling System)
and remove hoses from radiator. Remove engine ther-
mostat and reinstall thermostat housing. Install suit-
able flushing gun to thermostat housing hose. Turn
on water, and when engine is filled, turn on air, but
no higher than 138 kPa (20 psi) in short blasts. Allow
engine to fill between blasts of air. Continue this pro-
cedure until water runs clean. Reinstall thermostat
using a new housing gasket. Fill cooling system (See
Refilling).
CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor-
rosion products are carried to the radiator and depos-
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be
removed with a two part cleaner (oxalic acid and
neutralizer) available in auto parts outlets. Follow
manufacturers directions for use.
ADJUSTMENTS
PROPER BELT TENSION
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of a Burroughs
gauge Special Tool C-4162. Because of space limita-
tions in the engine compartment, the use of the
gauge may be restricted. Raise the vehicle on a hoist
Fig. 37 Serpentine Drive Belt Wear Patterns
NSCOOLING SYSTEM 7 - 25
CLEANING AND INSPECTION (Continued)