1996 CHRYSLER VOYAGER oil pressure

(3) Remove the fork from the bearing thrust plate
(Fig. 22).
(4) Examine the condition of the bearing. It is pre-
lubricated and sealed and should not be immersed in
oil or solvent.
(5) The bearing should turn smoothly when held in
the hand under a light thrust load. A light drag
caused by the lubricant fill is normal. If the bearing
is noisy, rough, or dry, replace the complete bearing
assembly with a new bearing.
(6) The bearing has a plastic sleeve pre-lubricated
at assembly. Wipe out the old grease. Refill the sleeve
cavities and coat the inner surface with multipurpose
grease. If the liner is cracked or worn, replace the
bearing assembly.
(7) Check the condition of the spring clips. If the
clips are broken or distorted, replace the bearing
assembly.
INSTALLATION
(1) Before assembling the fork, lubricate the
rounded thrust pads and the spring clip cavities with
multipurpose grease.
(2) Assemble the fork to the bearing by sliding the
thrust pads under the spring clips. Be careful to
avoid distorting the spring clips. These clips prevent
the bearing thrust plate from rotating with the bear-
ing.
(3) Slide the bearing and fork assembly onto the
input shaft bearing retainer.
(4) Position the release shaft bushings in the hous-
ing and install the release shaft. A small amount of
bearing grease between the release shaft bushing
and the shaft is beneficial but not required. Install
the retainer clip in the shaft groove near the large
bushing.
(5) Install the release lever and retaining clip on
the outer end of the release shaft.
CLEANING AND INSPECTION
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty opera-
tion.
During inspection, note if any components are con-
taminated. Look for evidence of oil, grease, or water/
road splash on clutch components.
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main
seal and/or transaxle input shaft. Oil leaks produce a
residue of oil on the transaxle housing interior, clutch
cover and flywheel. Heat buildup caused by slippage
can bake the oil residue onto the components. This
glaze-like residue ranges in color from amber to
black.
GREASE CONTAMINATION
Grease contamination is usually a product of over-
lubrication. During clutch service, apply only a small
amount of grease to the input shaft splines. Excess
grease may be thrown off during operation, contami-
nating the disc.
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by
driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing
clutch components to become contaminated. Facing of
disc will absorb moisture and bond to the flywheel
and/or, pressure plate, if vehicle is allowed to stand
for some time before use. If this condition occurs,
replacement of clutch assembly may be required.
Drive the vehicle until normal clutch operating tem-
perature has been obtained. This will dry off disc
assembly, pressure plate, and flywheel.
CLEANING PRECAUTIONS
Condensation from steam vapors tend to accumu-
late on the internal clutch mechanism when the vehi-
cle is steam cleaned. Facing of disc will absorb
moisture and will bond to flywheel and/or pressure
plate, if vehicle is allowed to stand for some time
before use. If this condition occurs, it may require
replacement of clutch assembly. After cleaning, drive
the vehicle to its normal clutch operating tempera-
ture. This will dry off disc assembly, pressure plate,
and flywheel.
Fig. 22 Clutch Release Fork
NS/GSCLUTCH 6 - 15
REMOVAL AND INSTALLATION (Continued)

COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELTS................ 1
AUTOMATIC TRANSMISSION OIL COOLERÐ
2.4L................................. 3
COOLANT RECOVERY SYSTEM (CRS)....... 3
COOLANT.............................. 3
COOLING SYSTEM....................... 2
ENGINE BLOCK HEATER.................. 5
ENGINE THERMOSTAT.................... 3
RADIATOR PRESSURE CAP................ 4
RADIATOR............................. 3
WATER PUMPS......................... 3
DESCRIPTION AND OPERATION
COOLANT PERFORMANCE................. 6
RADIATOR HOSES AND CLAMPS........... 6
WATER PIPESÐ3.0L ENGINE.............. 6
WATER PUMPÐ3.3/3.8L ENGINES.......... 7
WATER PUMPÐ2.4L ENGINE.............. 6
WATER PUMPÐ3.0L ENGINE.............. 6
DIAGNOSIS AND TESTING
ACCESSORY DRIVE BELT.................. 7
COOLING SYSTEM DIAGNOSIS............. 8
DEAERATION.......................... 16
ELECTRIC FAN MOTOR TEST.............. 14
LOW COOLANT LEVEL AERATION.......... 15
PRESSURE TESTING RADIATOR CAP....... 15
RADIATOR CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK.............. 15
RADIATOR COOLANT FLOW TEST.......... 14
RADIATOR FAN CONTROL................ 14
TEMPERATURE GAUGE INDICATION........ 16
TESTING COOLING SYSTEM FOR LEAKS.... 14
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE........ 16
COOLANT LEVEL SERVICE................ 16COOLANTÐADDING ADDITIONAL.......... 16
COOLING SYSTEMÐDRAINING............ 16
COOLING SYSTEMÐREFILLING........... 16
REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELTSÐ2.4L.......... 23
ACCESSORY DRIVE BELTSÐ3.0L.......... 24
ACCESSORY DRIVE BELTÐ3.3/3.8L........ 24
ENGINE BLOCK HEATER................. 23
FAN MODULE.......................... 22
RADIATOR DRAINCOCK.................. 21
RADIATOR............................ 21
THERMOSTATÐ2.4L ENGINE............. 19
THERMOSTATÐ3.0L ENGINE............. 20
THERMOSTATÐ3.3/3.8L ENGINES......... 20
WATER PUMP INLET TUBEÐ2.4L ENGINE . . . 17
WATER PUMPÐ3.3/3.8L ENGINES......... 19
WATER PUMPÐ2.4L ENGINE............ 17
WATER PUMPÐ3.0L ENGINE............. 18
CLEANING AND INSPECTION
ACCESSORY DRIVE BELT................. 25
CHEMICAL CLEANING................... 25
COOLING SYSTEM CLEANING............. 25
RADIATOR PRESSURE CAP............... 25
REVERSE FLUSHING THE ENGINE......... 25
REVERSE FLUSHING THE RADIATOR....... 25
WATER PUMP......................... 24
ADJUSTMENTS
BELT TENSION CHART................... 26
BELT TENSION GAUGE METHOD........... 26
PROPER BELT TENSION................. 25
SPECIFICATIONS
COOLING SYSTEM CAPACITY............. 26
TORQUE CHART........................ 26
SPECIAL TOOLS
COOLING............................. 26
GENERAL INFORMATION
ACCESSORY DRIVE BELTS
The accessory drive system utilizes two different
style of drive belts. The conventional V-belt and the
Poly-V belt are used to drive the generator, air con-
ditioning compressor, power steering pump and waterpump. Satisfactory performance of these belts
depends on belt condition and proper belt tension.
Belt tensioning should be performed with the aid of a
Burroughs gauge Special Tool C-4162. Because of
space limitations in the engine compartment, the use
of the gauge may be restricted. Raise the vehicle on a
hoist and then remove the splash shield to gain
access to the drive belts.
NSCOOLING SYSTEM 7 - 1

COOLING SYSTEM
The cooling system has a radiator, coolant, electric fan
motor, shroud, pressure cap, thermostat, coolant reserve
system, transmission oil cooler, a water pump to circulate
the coolant, hoses, and clamps to complete the circuit.
²When Engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²
When Engine is warm: thermostat is open, cooling
system has bypass flow and coolant flow through radia-
tor.
Its primary purpose is to maintain engine temper-
ature in a range that will provide satisfactory engine
performance and emission levels under all expected
driving conditions. It also provides hot water (cool-
ant) for heater performance and cooling for automatic
transmission oil. It does this by transferring heat
from engine metal to coolant, moving this heated
coolant to the radiator, and then transferring this
heat to the ambient air.
Coolant flow circuits for 2.4L and 3.3/3.8L engines
are shown in (Fig. 1), and 3.0L engine coolant rout-
ing is shown in (Fig. 2)
Fig. 1 Cooling System Operation 2.4L and 3.3/3.8L Engines
Fig. 2 Cooling System Operation 3.0L Engine
7 - 2 COOLING SYSTEMNS
GENERAL INFORMATION (Continued)

COOLANT RECOVERY SYSTEM (CRS)
This system works with the radiator pressure cap
to use thermal expansion and contraction of the cool-
ant to keep the coolant free of trapped air. Provides a
convenient and safe method for checking coolant
level and adjusting level at atmospheric pressure
without removing the radiator pressure cap. It also
provides some reserve coolant to cover deaeration
and evaporation or boiling losses. All vehicles are
equipped with this system and take various shapes
and forms. (Fig. 3) shows a typical system in the typ-
ical location.
See Coolant Level Service, and Deaeration, and
Pressure Cap sections for operation and service.
AUTOMATIC TRANSMISSION OIL COOLERÐ2.4L
Oil cooler is internal oil to coolant type, mounted
in the radiator left tank (Fig. 4). Rubber oil lines feed
the oil cooler and the automatic transmission. Use
only approved transmission oil cooler hose. Since
these are molded to fit space available, molded hoses
are recommended.
ENGINE THERMOSTAT
The engine cooling thermostats are a wax pellet
driven, reverse poppet choke type. They are designed
to provide the fastest warm up possible by prevent-
ing leakage through them and to guarantee a mini-
mum engine operating temperature of 88 to 93ÉC
(192 to 199ÉF). They also automatically reach wide
open so they do not restrict flow to the radiator as
temperature of the coolant rises in hot weather to
around 104ÉC (220ÉF). Above this temperature the
coolant temperature is controlled by the fan, the
radiator, and the ambient temperature, not the ther-
mostat.
WATER PUMPS
A quick test to tell whether the pump is working is
to see if the heater warms properly. A defective pump
can not circulate heated coolant through the long
heater hose.The water pump on all models can
be replaced without discharging the air condi-
tioning system.
COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves. Cool-
ant then carries this heat to the radiator, where the
tube/fin assemblies of these components can give it
up to the air.
The use of aluminum cylinder heads, intake mani-
folds, and water pumps requires special corrosion
protection. MopartAntifreeze or the equivalent is
recommended for best engine cooling without corro-
sion, when mixed only to a freeze point of -37ÉC
(-35ÉF) to -59ÉC (-50ÉF). If it loses color or becomes
contaminated, drain, flush, and replace with fresh
properly mixed solution.
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended.
RADIATOR
The radiators are cross-flow types (horizontal
tubes) with design features that provide greater
strength along with sufficient heat transfer capabili-
Fig. 3 Coolant Recovery System
Fig. 4 Automatic Transmission Oil Cooler
NSCOOLING SYSTEM 7 - 3
GENERAL INFORMATION (Continued)

ties to keep the engine satisfactorily cooled (Fig. 5),
(Fig. 6), (Fig. 7) and (Fig. 8).
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.
If the plastic tank is damaged, replace the radia-
tor.
RADIATOR PRESSURE CAP
The radiator is equipped with a pressure cap that
releases excessive cooling system pressure; maintain-
ing a range of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises thecoolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting allowing coolant to return to radiator
from coolant reserve system tank by vacuum through
connecting hose.If valve is stuck shut, or the
coolant recovery hose is pinched, the radiator
hoses will be collapsed on cool down. Clean the
vent valve (Fig. 9) and inspect coolant recovery
hose routing, to ensure proper sealing when
boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.
Fig. 5 Cooling ModuleÐ2.4L
Fig. 6 Cooling ModuleÐTrailer Tow (With Rear A/C)
7 - 4 COOLING SYSTEMNS
GENERAL INFORMATION (Continued)

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

WARNING: WITH TOOL IN PLACE, PRESSURE
WILL BUILD UP FAST. EXCESSIVE PRESSURE
BUILT UP, BY CONTINUOUS ENGINE OPERATION,
MUST BE RELEASED TO A SAFE PRESSURE
POINT. NEVER PERMIT PRESSURE TO EXCEED 138
kPa (20 psi).
If the needle on the dial does not fluctuate, race
the engine a few times. If an abnormal amount of
coolant or steam emits from the tail pipe, it may
indicate a coolant leak caused by a faulty head gas-
ket, cracked engine block, or cracked cylinder head.
There may be internal leaks that can be deter-
mined by removing the oil dipstick. If water globules
appear intermixed with the oil it will indicate an
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
RADIATOR CAP TO FILLER NECK SEAL PRESSURE
RELIEF CHECK
The pressure cap upper gasket (seal) pressure
relief can be checked by removing the overflow hose
at the radiator filler neck nipple (Fig. 13). Attach the
Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gas-
ket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at 55 kPa (8 psi) minimum.
WARNING: THE WARNING WORDS ªDO NOT
OPEN HOTº ON THE RADIATOR PRESSURE CAP IS
A SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
timeexceptfor the following purposes:
(1) Check and adjust coolant freeze point. By add-
ing or subtracting coolant through CRS bottle.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT 15 MINUTES BEFORE REMOVING
CAP. THEN PLACE A SHOP TOWEL OVER THE CAP
AND WITHOUT PUSHING DOWN ROTATE COUN-
TERCLOCKWISE TO THE FIRST STOP. ALLOW FLU-
IDS TO ESCAPE THROUGH THE OVERFLOW TUBE
AND WHEN THE SYSTEM STOPS PUSHING COOL-
ANT AND STEAM INTO THE CRS TANK AND PRES-
SURE DROPS PUSH DOWN AND REMOVE THE CAP
COMPLETELY. SQUEEZING THE RADIATOR INLET
HOSE WITH A SHOP TOWEL (TO CHECK PRES-
SURE) BEFORE AND AFTER TURNING TO THE
FIRST STOP IS RECOMMENDED.
PRESSURE TESTING RADIATOR CAP
Dip the pressure cap in water, clean any deposits
off the vent valve or its seat and apply cap to end of
Radiator Pressure Tool. Working the plunger, bring
the pressure to 104 kPa (15 psi) on the gauge. If the
pressure cap fails to hold pressure of at least 97 kPa
(14 psi) replace cap. SeeCAUTION.
If the pressure cap tests properly while positioned
on Radiator Pressure Tool (Fig. 14), but will not hold
pressure or vacuum when positioned on the radiator.
Inspect the radiator filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
CAUTION: Radiator Pressure Tool is very sensitive
to small air leaks that will not cause cooling system
problems. A pressure cap that does not have a his-
tory of coolant loss should not be replaced just
because it leaks slowly when tested with this tool.
Add water to the tool. Turn tool upside down and
recheck pressure cap to confirm that cap is bad.
LOW COOLANT LEVEL AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
Fig. 13 Radiator Pressure Cap Filler Neck
Fig. 14 Pressure Testing Radiator Cap
NSCOOLING SYSTEM 7 - 15
DIAGNOSIS AND TESTING (Continued)

at running operating temperature the high pressure
inlet tank runs full and the low pressure outlet tank
drops:
²Transmission oil will become hotter.
²High reading shown on the temperature gauge.
²Air in the coolant can cause loss of flow through
the heater.
²Exhaust gas leaks into the coolant also can
cause the same problems.
DEAERATION
Air can only be removed from the system by gath-
ering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the CRS
tank by thermal expansion of the coolant. It then
escapes to the atmosphere in the CRS tank and is
replaced with solid coolant on cool down.
TEMPERATURE GAUGE INDICATION
At idle with Air Conditioning off the temperature
gauge will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to
about 1/2 gauge travel. This is normal.
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE
Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the reserve tank (Fig. 3). The coolant level
should be between the minimum and maximum
marks.
COOLANTÐADDING ADDITIONAL
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant reserve tank.
Use only 50/50 mix of ethylene glycol type antifreeze
and water.
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended.
COOLANT LEVEL SERVICE
The cooling system is closed and designed to main-
tain coolant level to the top of the radiator.
When servicing requires a coolant level check in
the radiator, the engine must beoffandnotunder
pressure. Drain several ounces of coolant from the
radiator draincock while observing the CoolantRecovery System (CRS) Tank. Coolant level in the
CRS tank should drop slightly. Then remove the radi-
ator cap. The radiator should be full to the top. If
not, and the coolant level in the CRS tank is at the
MIN mark there is an air leak in the CRS system.
Check hose or hose connections to the CRS tank,
radiator filler neck or the pressure cap seal to the
radiator filler neck for leaks.
COOLING SYSTEMÐDRAINING
Without removing radiator pressure cap and
with system not under pressure,shut engine off
and open draincock. The coolant reserve tank should
empty first, then remove radiator pressure cap. (if
not, see Testing Cooling System for leaks). To vent
2.4L engine remove the coolant temperature sensor
located above water outlet housing (Fig. 15). The 3.0/
3.3/3.8L engines have an air bleed vent on the ther-
mostat.
Removal of a sensor is required because the ther-
mostat does not have an air vent. Sensor removal
allows an air bleed for coolant to drain from the
engine block.
COOLING SYSTEMÐREFILLING
First clean system to remove old coolant, see Cool-
ing System Cleaning.
Fill the system, using the correct antifreeze as
described in the Coolant Section. Fill the system to
50 percent of its capacity with 100 percent glycol.
Then complete filling system with water. The 2.4L
engine requires venting by removal of the coolant
sensor on top of the water outlet connector (Fig. 15).
When coolant reaches this hole:
²Install coolant sensor and tighten to 7 N´m (60
in. lbs.) for 2.4L Engines.
Fig. 15 Coolant Temperature SensorÐ2.4L Engine
Drain/Fill
7 - 16 COOLING SYSTEMNS
DIAGNOSIS AND TESTING (Continued)