1996 CHRYSLER VOYAGER radiator

INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE...................... 1
FASTENER IDENTIFICATION................ 4
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS..................... 4METRIC SYSTEM........................ 7
TORQUE REFERENCES................... 7
VEHICLE IDENTIFICATION NUMBER.......... 1
VEHICLE SAFETY CERTIFICATION LABEL..... 1
VIN CHECK DIGIT........................ 1
GENERAL INFORMATION
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 1) is located
on the rear shut face of the driver's door. This label
indicates date of manufacture (month and year),
Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR) front, Gross Axle Weight Rat-
ing (GAWR) rear and the Vehicle Identification Num-
ber (VIN). The Month, Day and Hour of manufacture
is also included.
When it is necessary to contact the manufacturer
regarding service or warranty, the information on the
Vehicle Safety Certification Label would be required.
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel, near the left windshield
pillar (Fig. 2). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
VIN CHECK DIGIT
To protect the consumer from theft and possible
fraud, the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Plate (Fig. 3) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.Fig. 1 Vehicle Safety Certification Label
Fig. 2 Vehicle Identification Number (VIN Plate)
NSINTRODUCTION 1

INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE...................... 1
E-MARK LABEL......................... 1MANUFACTURER PLATE.................. 3
VEHICLE IDENTIFICATION NUMBER......... 1
GENERAL INFORMATION
E-MARK LABEL
An E-mark Label (Fig. 1) is located on the rear
shut face of the driver's door. The label contains the
following information:
²Date of Manufacture
²Month-Day-Hour (MDH)
²Vehicle Identification Number (VIN)
²Country Codes
²Regulation Number
²Regulation Amendment Number
²Approval Number
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel next to the left A-pillar
(Fig. 2). The VIN consists of 17 characters in a com-
bination of letters and numbers that provide specific
information about the vehicle. Refer to the VIN
Decoding Information Table to interpret VIN code.
VIN CHECK DIGIT
To protect the consumer from theft and possible
fraud the manufacturer is required to include a check
Digit at the ninth position of the VIN. The check
digit is used by the manufacturer and government
agencies to verify the authenticity of the vehicle and
official documentation. The formula to use the check
digit is not released to the general public.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Plate is located (Fig. 3) in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
BODY CODE PLATEÐLINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, 14, AND 15
Open Space
Fig. 1 E-Mark Label
Fig. 2 VIN PLATE LOCATION
NS/GSINTRODUCTION 1

DIGITS 5 THROUGH 8
Primary Paint
See Group 23, Body for color codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Paint
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²ECB = 2.0L 4cyl 16 valve SOHC gasoline
²EDZ = 2.4 L 4 cyl. 16 valve DOHC gasoline
²ENC = 2.5 L 4 cyl. Turbo Diesel (Intercooler)
²EGA = 3.3 L 6 cyl. gasoline
²EGH = 3.8 L 6 cyl. gasoline
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGL = 41TE 4-speed Electronic Automatic Tran-
saxle
²DD3 = A-598 5±speed Manual TransaxleDIGIT 4
Open Space
DIGIT 5
Market Code
²B = International
²M = Mexico
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number (VIN)
Refer to Vehicle Identification Number (VIN) para-
graph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate contin-
ued (CTD).
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
MANUFACTURER PLATE
The Manufacturer Plate (Fig. 4) is located in the
engine compartment on the radiator closure panel
crossmember adjacent to the Body Code Plate. The
plate contains five lines of information:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
Fig. 3 Body Code Plate
Fig. 4 Manufacturer Plate
NS/GSINTRODUCTION 3
GENERAL INFORMATION (Continued)

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles) or every other
interval shown on Schedule ± B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter on 2.4L engines.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Change automatic transmission fluid.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
NSLUBRICATION AND MAINTENANCE 0 - 3

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULE............... 2
MAINTENANCE SCHEDULEÐ
DIESEL ENGINE....................... 2SCHEDULEÐA (DIESEL).................. 2
SCHEDULEÐB (DIESEL).................. 3
UNSCHEDULED INSPECTION.............. 2
GENERAL INFORMATION
MAINTENANCE SCHEDULE
Refer to the 1998 GS Service Manual for Gasoline
Engine and non-engine related Maintenance Sched-
ules.
MAINTENANCE SCHEDULEÐDIESEL ENGINE
The following are engine related Maintenance
items which are unique to Diesel engine-equipped
vehicles. Refer to the 1998 GS Service Manual for
Gasoline Engine and non-engine related Maintenance
Schedules.
The service intervals are based on odometer read-
ings in kilometers. There are two maintenance sched-
ules that show proper service intervals. Use the
schedule that best describes the conditions the vehi-
cle is operated under.Schedule-Alists all the sched-
uled maintenance to be performed under normal
operating conditions.Schedule-Bis the schedule for
vehicles that are operated under one or more of the
following conditions:
²Day and night temperatures are below freezing.
²Stop and go driving.
²Long periods of engine idling.
²Driving in dusty conditions.
²Short trips of less than 5 miles.
²Operation at sustained high speeds during hot
weather above 32ÉC (90ÉF).
²Taxi, police or delivery service.
²Trailer towing.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on ScheduleÐA (7,500 miles) or every other
interval shown on ScheduleÐ B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter.
SCHEDULEÐA (DIESEL)
1 000 KM
²Change engine oil.
²Change engine oil filter.
²Check all fluid levels.
²Check correct torque, intake manifold mounting
nuts.
²Check correct torque, exhaust manifold mount-
ing nuts.
²Check correct torque, turbocharger mounting
nuts.
²Check correct torque, water manifold bolts.
10 000 KM
²Change engine oil.
²Change engine oil filter.
20 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
0 - 2 LUBRICATION AND MAINTENANCENS/GS

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)