2002 CHRYSLER VOYAGER drive belt

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Page 286 of 2399

CHRYSLER VOYAGER 2002 Service Manual (4) Install the inlet tube (Fig. 36). Tighten bolts to
28 N´m (250 in. lbs.).
(5) Connect radiator lower hose (Fig. 34) and
heater return hose (if equipped with engine oil
cooler) (Fig. 35) to the in

Page 290 of 2399

CHRYSLER VOYAGER 2002 Service Manual COOLING 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM.........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM.....................

COOLING 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM.........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM.............................1
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TEST....................6
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK.................7
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION....................7CLEANING.............................7
INSPECTION...........................7
SPECIFICATIONS
SPECIFICATIONS - TORQUE.............8
SPECIFICATIONS - COOLING SYSTEM
CAPACITY............................8
ACCESSORY DRIVE.......................9
ENGINE...............................14
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible, maintains
normal operating temperature and prevents over-
heating.
The cooling system also provides a means of heat-
ing the passenger compartment. The cooling system
is pressurized and uses a centrifugal water pump to
circulate coolant throughout the system. A separate
and remotely mounted, pressurized coolant tank
using a pressure/vent cap is used.
COOLING SYSTEM COMPONENTS
The cooling system consists of:
²Charge Air Cooler
²Electric Cooling Fans
²A aluminum-core radiator with plastic side
tanks
²A separate pressurized coolant tank
²A pressure/vent cap on the coolant tank
²Fan shroud
²Thermostat
²Coolant
²Low coolant warning lamp
²Coolant temperature gauge
²Water pump
²Hoses and hose clamps
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
(1) PROLONGED IDLE, VERY HIGH AMBIENT
TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
OR STEEP GRADES.
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.
(2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(3) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt
²Brakes (possibly dragging)
²Changed parts (incorrect water pump)
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only.
RGCOOLING 2.5L TURBO DIESEL7a-1
ProCarManuals.com

Page 293 of 2399

CHRYSLER VOYAGER 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
5. Coolant level low in the coolant
tank (air will build up in the cooling
system causing the thermostat to
open late).5. Check and correct coolant
leaks.
6. Cylin

CONDITION POSSIBLE CAUSES CORRECTION
5. Coolant level low in the coolant
tank (air will build up in the cooling
system causing the thermostat to
open late).5. Check and correct coolant
leaks.
6. Cylinder head gasket leaking
allowing exhaust gases to enter the
cooling system causing the
thermostat to open late.6. (a) Check for cylinder head
gasket leaks with a
commercially available leak
tester. (b) Check for coolant in
engine oil. Inspect for white
steam emitting from exhaust
system. Repair as necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and
replace as necessary.
8. Loose accessory drive belt (water
pump slipping).8. Check and correct as
necessary.
9. Air leak on the suction side of the
water pump allowing air to build up
in the cooling system causing the
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS
BLOWING OFF STEAM
AND/OR COOLANT.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT TANK1. Pressure relief valve in pressure/
vent cap is defective.1. Check condition of
pressure/vent cap and cap
seals.
2. Head gasket leak or cracked
cylinder head.2. Repair as necessary.
COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP
BLOWOFF. GAUGE IS
READING HIGH OR HOT1. Coolant leaks in radiator, cooling
system hoses, water pump, or
engine.1. Pressure test cooling system
and repair as necessary.
HOSE OR HOSES
COLLAPSE WHEN
ENGINE IS COOLING1. Vacuum created in cooling system
on engine cool-down is not being
relieved through pressure/vent cap.1. Cap relief valve stuck.
Replace if necessary.
NOISY FAN 1. Cooling fan blades loose. 1. Replace cooling fan
assembly.
2. Cooling fan blades striking a
surrounding object.2. Locate point of fan blade
contact and repair as
necessary.
3. Air obstructions at radiator or A/C
condensor.3. Remove obstructions or
clean debris from radiator or
A/C condensor.
7a - 4 COOLING 2.5L TURBO DIESELRG
COOLING 2.5L TURBO DIESEL (Continued)
ProCarManuals.com

Page 294 of 2399

CHRYSLER VOYAGER 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR
CONDITIONER
PERFORMANCE
(COOLING SYSTEM
SUSPECTED)1. Radiator and/or A/C condensor is
restricted, obstructed or dirty
(insects, leaves, etc.)1. Remo

CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR
CONDITIONER
PERFORMANCE
(COOLING SYSTEM
SUSPECTED)1. Radiator and/or A/C condensor is
restricted, obstructed or dirty
(insects, leaves, etc.)1. Remove restriction or clean
debris from radiator or A/C
condensor.
2. Engine is overheating (heat may
be transferred from radiator to A/C
condensor. High underhood
temperatures due to engine
overheating may also transfer heat
to A/C condensor).2. Correct overheating
condition.
3. The cooling system is equipped
with air seals at the radiator and/or
A/C condensor. If these seals are
missing or damaged, not enough air
flow will be pulled through the
radiator and A/C condensor.3. Check for missing or
damaged air seals. Repair as
necessary.
INADEQUATE HEATER
PERFORMANCE. MAY BE
ACCOMPANIED BY LOW
GAUGE READING1. Diesel engines, due to their
inherent efficiency are slower to
warm up than gasoline powered
engines, and will operate at lower
temperatures when the vehicle is
unloaded.1. The lower gauge reading
may be normal.
2. Coolant level low. 2. Pressure test cooling system.
Repair leaks as necessary.
3. Obstruction in heater hose fitting
at engine.3. Remove heater hoses and
check for obstructions. Repair
as necessary.
4. Heater hose kinked. 4. Locate kinked area. Repair
as necessary.
5. Water pump is not pumping water
to heater core. When the engine is
fully warmed up, both heater hoses
should be hot to the touch. If only
one of the hoses is hot the water
pump may not be operating correctly.
The accessory drive belt may also
be slipping causing poor water pump
operation.5. Refer to water pumps in this
group. Repair as necessary. If a
slipping belt is detected, refer to
Engine Accessory Drive Belts in
this group. Repair as
necessary.
HEAT ODOR 1. Various heat shields are used at
certain drive line components. One
or more of these shields may be
missing.1. Locate missing shields.
Repair or replace as necessary.
2. Is temerature gauge reading
above the normal range?2. Refer to the previous
Temperature Gauge Reads
High in these Diagnostic
Charts. Repair as necessary.
3. Is the Cooling fan operating
correctly?3. Refer to Cooling System Fan
in this group for diagnosis.
Repair as necessary.
RGCOOLING 2.5L TURBO DIESEL7a-5
COOLING 2.5L TURBO DIESEL (Continued)
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Page 297 of 2399

CHRYSLER VOYAGER 2002 Service Manual SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Water Pump Housing Nuts 24.4 18 215
Thermostat Housing Bolts 27.5 21 Ð
Accessory Drive Be

Page 298 of 2399

CHRYSLER VOYAGER 2002 Service Manual ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS - ACCESSORY BELT
TENSION.............................9
BELT TENSIONER
REMOVAL.............................9
INSTALLATION.....

Page 299 of 2399

CHRYSLER VOYAGER 2002 Service Manual IDLER PULLEY
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
CAUTION: IDLER PULLEY RETAINING BOLT HAS
LEFT HAND THREAD
(2) Remove the idler pu

Page 300 of 2399

CHRYSLER VOYAGER 2002 Service Manual DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. (a) Replace belt (auto-tensioned
belts)
2. Fau

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