1996 CHRYSLER VOYAGER Service Manual

COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
COOLANT PRESSURE BOTTLE............ 1
COOLING SYSTEM Ð 2.0L GASOLINE...... 1
COOLING SYSTEM Ð 2.5L VM DIESEL..... 1
LOW COOLANT LEVEL SENSOR........... 1
RADIATOR............................ 2
DESCRIPTION AND OPERATION
AUTOMATIC BELT TENSIONER............ 6
BELT TENSION......................... 5
COOLANT PERFORMANCE............... 5
PRESSURE/VENT CAP................... 4
THERMOSTAT OPERATION............... 4
THERMOSTAT......................... 6
WATER PUMP......................... 3
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT........... 7
DRAINING COOLING SYSTEM............. 7
REFILLING COOLING SYSTEM............ 7
REMOVAL AND INSTALLATION
ENGINE THERMOSTATÐ 2.0L GASOLINE . . . 9GENERATOR/POWER STEERING BELT Ð 2.5L
VM DIESEL......................... 10
RADIATOR Ð 2.5L VM DIESEL........... 9
THERMOSTAT Ð 2.5L VM DIESEL......... 9
WATER PUMP BELT Ð 2.5L VM DIESEL . . . 10
WATER PUMP Ð 2.0L GASOLINE......... 7
WATER PUMP Ð 2.5L VM DIESEL........ 8
CLEANING AND INSPECTION
WATER PUMP........................ 10
ADJUSTMENTS
BELT TENSION CHART................. 11
BELT TENSION GAUGE METHOD......... 11
SPECIFICATIONS
COOLING SYSTEM CAPACITY............ 12
TORQUE CHART...................... 12
SPECIAL TOOLS
COOLING............................ 12
GENERAL INFORMATION
COOLING SYSTEM Ð 2.0L GASOLINE
The 2.0L gasoline engine cooling system consists of
an engine cooling module, thermostat, coolant, a
water pump to circulate the coolant. The engine cool-
ing module may consist of a radiator, electric fan
motors, fan, shroud, coolant reserve system, hoses,
clamps, air condition condenser.
²When the Engine is cold: The thermostat is
closed; the cooling system has no flow through the
radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open;
the cooling system has flow through radiator, engine,
heater system and bypass.
COOLING SYSTEM Ð 2.5L VM DIESEL
The cooling system has a radiator, coolant, electric
fan motors, shroud, pressure cap, thermostat, coolant
pressure bottle, hoses, a water pump to circulate the
coolant, to complete the circuit. Coolant flow for the
VM diesel engine is shown in (Fig. 1).
COOLANT PRESSURE BOTTLE
2.5L VM DIESEL
This system works with the pressure cap to use
thermal expansion and contraction of the coolant to
keep the coolant free of trapped air. It provides some
reserve coolant to cover minor leaks and evaporation
or boiling losses. The coolant pressure bottle location
for 2.5L diesel is above the cylinder head cover (Fig.
2).
LOW COOLANT LEVEL SENSOR
The low coolant level sensor checks for low coolant
level in the coolant tank. A signal will be sent from
this sensor to the Body Control Module (BCM). When
the BCM determines low coolant level for 30 contin-
uous seconds, the instrument panel mounted low
coolant level warning lamp will be illuminated. The
sensor is located on the front side of the coolant tank
(Fig. 4). For information, refer to Group 8E, Instru-
ment Panel and Gauges.
If this lamp is illuminated, it indicates the need to
fill the coolant tank and check for leaks.
NS/GSCOOLING SYSTEM 7 - 1

RADIATOR
The radiators are cross-flow types (horizontal
tubes) with design features that provide greater
strength along with sufficient heat transfer capabili-
Fig. 1 Cooling System Operation ± 2.5L VM Diesel
Fig. 2 Coolant Pressure Bottle ± 2.5L VM Diesel
Fig. 3 Low Coolant Warning Sensor Connector ±
2.5L VM Diesel
7 - 2 COOLING SYSTEMNS/GS
GENERAL INFORMATION (Continued)

ties to keep the engine satisfactorily cooled (Fig. 5)
and (Fig. 6).
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.
DESCRIPTION AND OPERATION
WATER PUMP
2.0L GASOLINE
The water has a diecast aluminum body and hous-
ing with a stamped steel impeller. The water pumpbolts directly to the block (Fig. 7). Cylinder block to
water pump sealing is provided by a rubber O-ring.
The water pump is driven by the timing belt. Refer
to Group 9, Engine section for component removal to
access the water pump.
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
2.5L VM DIESEL
The Diesel engine water pump has an aluminum
body and housing with a stamped steel impeller. The
pump uses an O-ring gasket between body and hous-
ing. The water pump is driven by the accessory drive
belt, and the pump housing is bolted to the cylinder
block (Fig. 9).
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
Fig. 4 Low Coolant Level Sensor
Fig. 5 Cooling Module Ð2.0LGasoline
Fig. 6 Cooling Module ÐVM Diesel
NS/GSCOOLING SYSTEM 7 - 3
GENERAL INFORMATION (Continued)

THERMOSTAT OPERATION
2.5 VM DIESEL
The engine cooling thermostats are 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 (Fig. 10). The
thermostat has a hole to bleed off air in the cooling
system during engine warm up. The thermostat
begins to open at 80É C62É (176É F64É).
PRESSURE/VENT CAP
WARNING: Engine coolant can reach temperatures
of 200É fahrenheit or greater. If the cooling system
is opened with coolant at a high temperature, hot
coolant can be forced out of the system under high
pressures, causing personal injury. Allow system to
cool down prior to removing the pressure cap.
The pressure/vent cap is secured to the coolant
tank neck by a means of a cam lock system. This cap
releases excess pressure at some point within a
range of 90-117 kPa (13- 17 psi) for gasoline engines,
and 110±124 kPa (16±18 psi) for diesel engines. The
actual pressure relief point (in pounds) is labeled on
top of the cap (Fig. 11).
The cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi-
ator cooling capacity. The cap (Fig. 11) contains a
spring-loaded pressure relief valve. This valve opens
when system pressure reaches approximately 103
kPa (15 psi).
When the engine is cooling down, vacuum is
formed within the cooling system. To prevent collapse
of the radiator and coolant hoses from this vacuum, a
vacuum valve is used within the cap. This valve pre-
vents excessive pressure differences from occurring
between the closed cooling system and the atmo-
sphere. If the vacuum valve is stuck shut, the radia-
tor and/or cooling system hoses will collapse on cool-
down.
Fig. 7 Water PumpÐ2.0L Gasoline Engine
Fig. 8 Water PumpÐ2.0L Gasoline Engine
Fig. 9 Water PumpÐ2.5L VM Diesel
Fig. 10 Thermostat and Housing Ð 2.5L VM Diesel
7 - 4 COOLING SYSTEMNS/GS
DESCRIPTION AND OPERATION (Continued)