2002 CHRYSLER VOYAGER Service Manual

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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

Page 301 of 2399

CHRYSLER VOYAGER 2002 Service Manual Fig. 4 ACCESSORY DRIVE BELT REMOVAL
1 - BELT TENSIONER
2 - ACCESSORY DRIVE BELT
3 - IDLER PULLEY
4 - A/C COMPRESSOR CLUTCH
5 - CRANKSHAFT DAMPER/PULLEY
6 - WRENCH
Fig. 5 LOCKING/LOCKING BELT TENSIONER

Page 302 of 2399

CHRYSLER VOYAGER 2002 Service Manual INSTALLATION
INSTALLATION-ACCESSORY DRIVE BELT
(1) Install the accessory drive belt in proper popsi-
tion (Fig. 8).
(2) Unlock belt tensioner by removing punch and
apply tension to accessory drive bel

Page 303 of 2399

CHRYSLER VOYAGER 2002 Service Manual ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION.........................15
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING.............15
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
S

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION.........................15
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING.............15
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
SERVICE............................16
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................16
STANDARD PROCEDURE - COOLANT
LEVEL CHECK........................16
STANDARD PROCEDURE - COOLING
SYSTEM FILLING.....................16
STANDARD PROCEDURE - COOLING
SYSTEM DRAINING....................17
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................18
INSTALLATION.........................18
ENGINE COOLANT TEMP SENSOR
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
ENGINE COOLANT THERMOSTAT
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
RADIATOR
DESCRIPTION.........................21
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................22
RADIATOR DRAINCOCK
REMOVAL.............................22
INSTALLATION.........................22
WATER PUMP
DESCRIPTION.........................23OPERATION...........................23
REMOVAL
REMOVAL - WATER PUMP..............23
REMOVAL - WATER PUMP HOUSING......23
CLEANING............................23
INSTALLATION
INSTALLATION - WATER PUMP..........23
INSTALLATION - WATER PUMP HOUSING . . 24
RADIATOR PRESSURE CAP
DESCRIPTION.........................25
OPERATION...........................25
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP...............25
DIAGNOSIS AND TESTING - PRESSURE
RELIEF TEST........................26
CLEANING............................26
INSPECTION..........................26
RADIATOR FAN
DESCRIPTION.........................26
OPERATION...........................27
DIAGNOSIS AND TESTING - RADIATOR FAN
MOTOR .............................27
REMOVAL.............................28
INSTALLATION.........................28
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS...........28
OPERATION - HOSE CLAMPS.............28
RADIATOR FAN RELAY
DESCRIPTION.........................29
OPERATION...........................29
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE.....29
REMOVAL - LOWER RADIATOR HOSE.....29
REMOVAL - COOLANT BYPASS HOSE.....30
INSTALLATION
INSTALLATION - UPPER RADIATOR HOSE . . 30
INSTALLATION - LOWER RADIATOR HOSE . 30
INSTALLATION - COOLANT BYPASS HOSE . 30
7a - 14 ENGINERG
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Page 304 of 2399

CHRYSLER VOYAGER 2002 Service Manual COOLANT
DESCRIPTION
Coolant flows through the engine water jackets
and cylinder heads absorbing heat produced by the
engine during operation. The coolant carries heat to
the radiator and heater core.

COOLANT
DESCRIPTION
Coolant flows through the engine water jackets
and cylinder heads absorbing heat produced by the
engine during operation. The coolant carries heat to
the radiator and heater core. Here it is transferred to
ambient air passing through the radiator and heater
core fins.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti-
freeze concentrationmust alwaysbe a minimum of
44 percent, year-round in all climates.If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.
100 Percent Ethylene-GlycolÐShould Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300 deg. F). This temperature is hot
enough to melt plastic and soften solder. The
increased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at -22 deg. C (-8 deg. F ).
Propylene-glycol FormulationsÐShould Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications.It's overall effec-
tive temperature range is smaller than that of ethyl-
ene-glycol. The freeze point of 50/50 propylene-glycol
and water is -32 deg. C (-26 deg. F). 5 deg. C higher
than ethylene-glycol's freeze point. The boiling point
(protection against summer boil-over) of propylene-
glycol is 125 deg. C (257 deg.F)at96.5 kPa (14 psi),
compared to 128 deg. C (263 deg. F) for ethylene-gly-
col. Use of propylene-glycol can result in boil-over or
freeze-up in Chrysler vehicles, which are designed for
ethylene-glycol. Propylene glycol also has poorer heat
transfer characteristics than ethylene glycol. Thiscan increase cylinder head temperatures under cer-
tain conditions.
Propylene-glycol/Ethylene-glycol MixturesÐShould Not Be
Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING
Coolant concentration should be checked when any
additional coolant was added to system or after a
coolant drain, flush and refill. The coolant mixture
offers optimum engine cooling and protection against
corrosion when mixed to a freeze point of -37ÉC
(-34ÉF) to -59ÉC (-50ÉF). The use of a hydrometer or a
refractometer can be used to test coolant concentra-
tion.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mix-
ture. The higher the concentration of ethylene glycol,
the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of
60% by volume glycol).
A refractometer will test the amount of glycol in a
coolant mixture by measuring the amount a beam of
light bends as it passes through the fluid.
Some coolant manufactures use other types of gly-
cols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freez-
ing protection and corrosion protection and is not rec-
ommended.
CAUTION: Do not mix types of coolantÐcorrosion
protection will be severely reduced.
RGENGINE7a-15
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