1996 CHRYSLER VOYAGER air condition

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)

CONDITION - AND CHECKS DIAGNOSIS
Inadequate Air Conditioning Performance - Cooling System Suspected
(1) Check for plugged air side of condenser and
radiator front and rear.(1) Wash out with low-velocity water.
(2) Assure fan runs whenever A/C head pressure
exceeds 1724 kPa (250 psi).(2) Repair as necessary.
(3) Check for missing air seals-recirculating air path.
(4) Assure correct cooling system parts.
Battery Dead - Suspect Fan Current Draw as Cause
(1) With a good, fully charged battery. (1) a - Assure fan control is operating properly.
(1) b - See charging system in Electrical, Group 8B.
Hot Smell - Suspect Cooling System
(1) Was temperature gauge high? (1) a - Yes, See9Gauge Reads High9
(1) b - No. See 2, 3, 4, and 5.
(2) Heat shields all in place? (2) a - Yes, See 3, 4, and 5.
(2) b - Repair or replace heat shields.
(3) Fan control operating properly? (3) a - Yes, See 4 and 5.
(3) b - No, See Radiator Fan Control this section.
(4) Heat exchanger air side plugged? (4) Clean as required.
(5) Engine missing or running rich? (5) Repair as required.
Poor Driveability - Suspect Failed Open Thermostat.
(1) Check diagnostics - is code 17 set? (Engine too
cold for too long)(1) If yes, change thermostat.
Poor Heater Performance - Suspect Failed Open Thermostat
(1) Does gauge read low? (1) See 3
(2) Check coolant level. (2) See 3
(3) Check diagnostics - is code 17 set? (Engine too
cold for too long)(3) If yes, change thermostat. If no, check heater
bypass valve, which should be closed except in Max
A/C or off mode; if not, see Heater and Air Conditioning
Group, 24.
Steaming, Observe Water Vapor Through Grill or Head Gap at Standstill at Idle - In Wet Weather
(1) This is normal. It is moisture, snow, or water on the
outside of the radiator that evaporates when the
thermostat opens to put hot coolant into the radiator.
This usually occurs in cold weather with no fan or air
flow to blow it away.(1) Normal condition - no service required.
NSCOOLING SYSTEM 7 - 13
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)

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)

(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)