1996 CHRYSLER VOYAGER drain bolt

(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)

INSTALLATIONÐ2.4L ENGINE
(1) Place a new gasket (dipped in clean water) on
the engine outlet connector surface. Center the ther-
mostat in thermostat housing (Fig. 25).
(2) Place the engine outlet connector and gasket
over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Bolt outlet connector to thermostat housing
(Fig. 25). Tighten bolts to 28 N´m (250 in. lbs.).
(4) Refill the cooling system to the proper level.
Refer to Cooling System Refilling outlined in this sec-
tion for procedure
THERMOSTATÐ3.0L 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. 26).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
INSTALLATIONÐ3.0L ENGINE
(1) Center thermostat in water box pocket. Check
that the flange is seated correctly in the countersunk
portion of the intake manifold water box (Fig. 26)
and (Fig. 27).
(2) Install new gasket on water box.
(3) Install housing over gasket and thermostat
and tighten bolts to 12 N´m (105 in. lbs.).(4) Refill the cooling system to the proper level.
Refer to Cooling System Refilling outlined in this sec-
tion for procedure.
THERMOSTATÐ3.3/3.8L ENGINES
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Cooling System Draining in this
section.
(2) Remove thermostat housing bolts and housing
(Fig. 28).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
Fig. 26 Thermostat, Housing, and Water BoxÐ3.0L
Engine
Fig. 27 Thermostat InstalledÐ3.0L Engine
Fig. 28 Thermostat, Housing, and Water BoxÐ3.3/
3.8L Engines
7 - 20 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place a new gasket (dipped in water) on the
thermostat housing surface, center thermostat into
opening in the intake manifold water box.
(2) Place housing and gasket over the thermostat,
making sure thermostat is in the recess provided
(Fig. 28).
(3) Bolt housing to intake manifold, tighten bolts
to 28 N´m (250 in. lbs.).
(4) Refill the cooling system to the proper level.
Refer to Cooling System Refilling outlined in this sec-
tion for procedure.
RADIATOR
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(2) Drain cooling system. Refer to Draining Cool-
ing System of this section.
(3) Remove air intake resonator.
(4) Remove coolant reserve system tank to filler
neck tube hose.
(5) Disconnect fans from the connector located on
the left side of the fan module.
(6) Remove the Coolant Recovery System (CRS)
tank retaining screw from the upper radiator closure
panel crossmember.
(7) Disconnect the upper radiator mounting
screws from the crossmember. Disconnect the engine
block heater wire if equipped.
(8) Remove the upper radiator closure panel
crossmember. Refer to Group 23 Body for procedure.
(9) Remove air cleaner assembly.
(10) Disconnect automatic transmission oil cooler
lines at radiator and plug.
(11) Disconnect inlet and outlet hoses from the
radiator. Remove the lower hose clip from the fan
module.
(12) Remove A/C condenser fasteners and sepa-
rate the condenser from the radiator (Fig. 29). Verify
the condenser is supported in position.
(13) Remove A/C filter/dryer mounting bracket, 2
bolts to the fan module, and 2 nuts to the filter/dryer.
(14) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.INSTALLATION
(1)Be sure the air seals are in position before
radiator is installed.Slide radiator down into posi-
tion behind closure panel. Seat the radiator with the
rubber isolators into the mounting holes provided,
with a 10 lbs. force.
(2) Install A/C filter/dryer and mounting bracket
onto fan module.
(3) Install Air Conditioning Condenser onto the
radiator (Fig. 29).
(4) Unplug and connect automatic transmission
oil cooler lines to radiator.
(5) Install inlet and outlet radiator hoses (includ-
ing coolant reserve hose) and connect the fan motor
electrical connection.
(6) Install air cleaner assembly.
(7) Install the upper radiator closure panel cross-
member. Refer to Group 23 Body for procedure.
(8) Install the upper radiator mounting screws.
Tighten radiator mounting bolts to 12 N´m (105 in.
lbs.). Connect the engine block heater wire if
equipped.
(9) Install the Coolant Recovery System (CRS)
tank retaining screw to the upper radiator closure
panel crossmember.
(10) Install air intake resonator.
(11) Fill cooling system. Refer to Cooling System
Filling in this section.
(12) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not rec-
ommended. Damage may occur to part. Draincock
should not be removed unless leakage observed.
(1) Turn the draincock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
Fig. 29 Air Conditioning Condenser Mounting
Fasteners
NSCOOLING SYSTEM 7 - 21
REMOVAL AND INSTALLATION (Continued)

the end of the threads turn back 1/8 turn and, pull
the stem (Fig. 30) from the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening until it snaps into place.
(2) Tighten the draincock stem by turning clock-
wise until it stops.
FAN MODULE
REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as a assem-
bly (Fig. 31).
(1) Raise the vehicle on hoist.
(2) Remove the radiator outlet hose from hose
retaining clip and remove clip from shroud.
(3) Remove lower auxiliary transmission cooler
lines from retaining clips on the fan module shroud,
if equipped.
(4) Lower the vehicle. Remove the air intake res-
onator from the throttle body and air cleaner assem-
bly.
(5) Disconnect the fans electrical connector
located on the left side of the fan module.
(6) Remove the Coolant Recovery System (CRS)
attaching screw from the upper crossmember.
(7) Remove upper grill to crossmember valence
panel.
(8) Disconnect the upper radiator mounts from the
crossmember. Remove the upper crossmember. Refer
to Group 23 Body for procedure.
(9) Remove the air cleaner assembly.
(10) Remove fan module retaining fasteners (Fig.
31).
(11) Remove upper auxiliary transmission cooler
lines from retaining clips on the fan module shroud,
if equipped.(12) Disconnect and plug the transmission line
from the radiator fitting on the lower left side.
(13) Raise vehicle on the hoist and remove the fil-
ter/drier, fan module and radiator mounting bolts
located on the lower right of the module.
(14) Lower the vehicle on hoist and remove the
upper fan module to radiator retaining clips.
(15) Remove the fan module from the vehicle.
INSTALLATION
(1) Install fan module assembly into attaching
clips on the radiator.
(2) Install the upper fan module to radiator
retaining clips.
(3) Raise vehicle on the hoist and install the fil-
ter/drier, fan module and radiator mounting fasten-
ers located on the lower right of the module.
(4) Lower the vehicle. Connect the transmission
line to the radiator fitting on the lower left side.
(5) Install the upper auxiliary transmission cooler
lines to the retaining clips on the fan module shroud,
if equipped.
(6) Install fan module retaining fasteners (Fig.
31). Tighten to 12 N´m (105 in. lbs.).
(7) Install the air cleaner assembly.
(8) Install the crossmember. Refer to Group 23
Body for procedure. Connect the upper radiator
mounts to the crossmember. Tighten fasteners to 12
N´m (105 in. lbs.).
(9) Install the Coolant Recovery System (CRS)
attaching screw to the upper crossmember. Tighten
to 2 N´m (18 in. lbs.).
(10) Install upper grill to crossmember valence
panel.
(11) Connect the fans to the connector located on
the left side of the fan module.
(12) Install the air intake resonator to the throttle
body and air cleaner assembly.
Fig. 30 Draincock Disassembled
Fig. 31 Fan Module
7 - 22 COOLING SYSTEMNS
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)

(3) Remove power steering pump bracket bolts and
set pump and bracket assembly aside. Power steering
lines do not need to be disconnected.
(4) Remove timing belt.
(5) Remove inner timing belt cover.
(6) Remove water pump attaching screws to engine
(Fig. 15).
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 16). Use small dabs of Mopar Sil-
icone Rubber Adhesive Sealant around the water
pump body to secure O-ring in place during installa-
tion.
CAUTION: Make sure O-ring gasket 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.). 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 inner timing belt cover.
(5) Install timing belt.
(6) Fill cooling system. SeeFilling Cooling Sys-
tem.
(7) Install power steering pump and accessory
drive belts.
WATER PUMP Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system. Refer to Draining Cool-
ing System in this Group.
(2) Remove the right inner splash shield (Fig. 17).
(3) Loosen the water pump pulley attaching bolts
(Fig. 18) before the accessory drive belt is removed.
(4) Loosen water pump accessory drive belts (Fig.
19). Remove water pump pulley.(5) Remove water pump attaching bolts and
remove pump.
INSTALLATION
(1) Install a new water pump to housing O-ring
gasket. Install pump and tighten the attaching bolts
to 22.6 N´m (205 in. lbs.)
Fig. 15 Water Pump Ð 2.0L Gasoline
Fig. 16 Water Pump Body Ð 2.0L Gasoline
Fig. 17 Right Side Splash Shield
Fig. 18 Water Pump and Pulley Ð 2.5 L VM Diesel
7 - 8 COOLING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)

(2) Install water pump pulley.
(3) Install drive belt, Refer to Accessory Drive
Belts, this Group. Tighten water pump pulley attach-
ing bolts to 27.5 N´m (240 in. lbs.)
(4) Install right inner splash shield.
(5) Refill cooling system. Refer to Refilling Cooling
System in this Group.
ENGINE THERMOSTATÐ 2.0L GASOLINE
REMOVAL
(1) Drain cooling system to the thermostat level or
below.
(2) Remove coolant recovery system (CRS) hose
and thermostat/engine outlet connector bolts.
(3) Remove thermostat and seal, and clean sealing
surfaces.
INSTALLATION
(1) Place the new thermostat assembly into the
thermostat housing/outlet connector. Align air bleed
vent with notch in cylinder head.
(2) Install thermostat housing/outlet connector
onto cylinder head and tighten bolts to 12.5 N´m (110
in. lbs.). Connect the upper radiator hose.
(3) Refill cooling system (seeRefilling System).
THERMOSTAT Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
section.(2) Remove radiator hose at thermostat cover.
(3) Remove thermostat cover bolts (Fig. 20).
(4) Remove Thermostat.
INSTALLATION
(1) Remove old gasket material from thermostat
housing and cover.
(2) Install new thermostat gasket.
(3) Install thermostat and tighten cover bolts to
10.8 N´m (96 in. lbs.).
(4) Install radiator hose.
(5) Refill cooling system. Refer to Refilling Cooling
System in this section.
RADIATOR Ð 2.5L VM DIESEL
REMOVAL
(1) Disconnect battery.
(2) Remove power steering reservoir attaching
bolts, and reposition reservoir.
(3) Remove radiator closure panel crossmember
(Fig. 21).
(4) Remove air cleaner housing and intake hose.
(5) Unplug fan module 4 pin wiring connector.
(6) Drain cooling system. Refer to Draining cooling
system in this section for procedure.
(7) Remove upper and lower Radiator Hoses.
(8) Remove radiator attaching bolts.
(9) Loosen A/C receiver/dryer lower bolt.
(10) Remove Radiator.
(11) Remove fan module from radiator.
Fig. 19 Water Pump Drive BeltÐ 2.5 L VM Diesel
Fig. 20 Thermostat and Housing Ð 2.5L VM Diesel
NS/GSCOOLING SYSTEM 7 - 9
REMOVAL AND INSTALLATION (Continued)