2002 CHRYSLER VOYAGER electr

(3) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
RADIATOR
DESCRIPTION
The radiator is a cross-flow type (horizontal tubes)
with design features that provide greater strength
along with sufficient heat transfer capabilities to
keep the engine satisfactorily cooled. The radiator
has plastic side tanks and aluminum cooling tubes.
OPERATION
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove radiator upper crossmember support.
(Refer to 23 - BODY/EXTERIOR/GRILLE OPENING
REINFORCEMENT - REMOVAL)
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.
(3) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(4) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(5) Disconnect coolant bypass hose (Fig. 11).
(6) Disconnect upper and lower hoses from the
radiator (Fig. 11).
(7) Remove the A/C condenser side brackets to
radiator attaching screws (Fig. 12). Separate the con-
denser from the radiator by lifting upward to disen-
gage from lower mounts (Fig. 12). Allow the
condenser to rest in front of radiator.
Fig. 10 THERMOSTAT HOUSING ASSEMBLY
1 - THERMOSTAT HOUSING GASKET
2 - THERMOSTAT HOUSING
3 - RETAINING BOLTS
4 - CYLINDER HEAD
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
Fig. 11 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE7a-21
ENGINE COOLANT THERMOSTAT (Continued)
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DIAGNOSIS AND TESTING - PRESSURE
RELIEF TEST
The pressure cap upper gasket (seal) pressure
relief can be checked by removing the overflow hose
at the radiator filler neck nipple (Fig. 21). Attach the
Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gas-
ket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at 55 kPa (8 psi) minimum.
WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
timeexceptfor the following purposes:
(1) Check and adjust coolant freeze point.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP COM-
PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
CLEANING
Use only a mild soap to clean the pressure cap.
INSPECTION
Hold the cap in your hand,top side up(Fig. 21).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.
Hold the cleaned cap in your hand,upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap.Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
RADIATOR FAN
DESCRIPTION
The dual radiator fans are mounted to the back
side of the radiator (Fig. 22). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
Fig. 21 Radiator Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - PRESSURE BOTTLE
8 - FILLER NECK
7a - 26 ENGINERG
RADIATOR PRESSURE CAP (Continued)
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OPERATION
RADIATOR FAN OPERATION CHART
COOLANT TEMPERATURE A/C PRESSURE
Fan Operation
Speeds:Initial Max Initial Max
Fan On: 104ÉC (220ÉF) 110ÉC (230ÉF) Fan
Speed Duty-Cycles
(Ramps-up) from
30% to 99%1,724 Kpa (250 psi) 2,068 Kpa (300 psi)
Fan Speed
Duty-Cycles
(Ramps-up) from
30% to 99%
Fan Off: 101ÉC (214ÉF) Fan Speed
Duty-Cycles
(Ramps-down) from
99% to 30%1,710 Kpa (248 psi) Fan Speed
Duty-Cycles
(Ramps-down) from
99% to 30%
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
RADIATOR FAN DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blade striking a surrounding
object.2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or A/C
condenser.3. Remove obstructions and/or
clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES
NOT OPERATE1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor, or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Defective A/C pressure
transducer.2. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
ELECTRIC RADIATOR FAN
OPERATES ALL THE TIME1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Check for low coolant level. 2. Add coolant as necessary.
3. Defective A/C pressure
transducer.3. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
RGENGINE7a-27
RADIATOR FAN (Continued)
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REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as an assem-
bly (Fig. 22).
(1) Remove the radiator upper crossmember. (Refer
to 23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL)
(2)
Disconnect the radiator fan electrical connectors.
(3) Remove radiator fan(s) retaining screw (Fig.
22).
(4) Remove the radiator fan(s) by lifting upward to
release from mounts.
INSTALLATION
(1) Install the radiator fan(s) into mounts and
attaching clips on the radiator.
(2) Install radiator fan(s) attaching screws (Fig.
22). Tighten to 5 N´m (45 in. lbs.).
(3) Connect the radiator fan(s) electrical connec-
tors.
(4) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION)
(5) Install the upper radiator mounts to the cross-
member bolts, if removed. Tighten to 8 N´m (70 in.
lbs.).
(6) Install the radiator upper hose to the support
clip (2.4L engine).
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS
The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,replace with the original Mopartequipment spring
type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 23).
OPERATION - HOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 24) to compress the
hose clamp.
Fig. 22 Radiator Fans
1 - SCREWS - RADIATOR FAN ATTACHING
2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN
4 - CLIPS - RADIATOR FAN LOWER
5 - MOUNT - LEFT RADIATOR FAN
6 - RADIATOR FAN - LEFT
Fig. 23 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
Fig. 24 Hose Clamp Tool
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
7a - 28 ENGINERG
RADIATOR FAN (Continued)
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information and location views for the various wire
harness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
AUDIO SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
6. SPEAKERS FAULTY. 6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP.
NO DISPLAY. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO MEMORY. 1. FUSE FAULTY. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF
REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
POOR RADIO
RECEPTION.1. ANTENNA FAULTY. 1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR OR
REPLACE ANTENNA, IF REQUIRED.
8A - 2 AUDIORS
AUDIO (Continued)
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ANTENNA BODY AND CABLE
DESCRIPTION
All models use a fixed-length stainless steel rod-
type antenna mast, installed at the right front fender
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable, and is not
grounded to any part of the vehicle.
OPERATION
To minimize static, the antenna base must have a
good ground. The coaxial antenna cable shield (the
outer wire mesh of the cable) is grounded to the
antenna base and the radio chassis.
The antenna coaxial cable has an additional dis-
connect, located near the right end of the instrument
panel. This additional disconnect allows the instru-
ment panel assembly to be removed and installed
without removing the radio.
The factory-installed Electronically Tuned Radios
(ETRs) automatically compensate for radio antenna
trim. Therefore, no antenna trimmer adjustment is
required or possible when replacing the receiver or
the antenna.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
The ohmmeter test lead connections for each test
are shown in (Fig. 1).
TEST 1
Test 1 determines of the antenna mast is insulated
from the base. Proceed as follows:
(1) Unplug the antenna coaxial cable from the
radio chassis and isolate. Remove the antenna mast.
(2) Connect an ohmmeter test lead to the inside
center of the antenna base. Connect the other test
lead to a metallic portion on the outside of the
antenna base. Check for continuity.
(3) There should be no continuity. If continuity is
found, replace the faulty or damaged antenna base
and cable assembly.
TEST 2
Test 2 checks the antenna for an open circuit as
follows:(1) Unplug the antenna coaxial cable connector
from the radio chassis. Remove the antenna mast.
The painted mast prevents measurement directly
through the mast.
(2) Connect an ohmmeter test lead to the inside
center of the antenna base. Connect the other test
lead to the center pin of the antenna coaxial cable
connector.
(3) Continuity should exist (the ohmmeter should
only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable
assembly. Replace the faulty base and cable if
required.
TEST 3
Test 3 checks the condition of the ground between
the antenna base and the vehicle body as follows:
(1) Connect one ohmmeter test lead to the fender
on an exposed metal area (paint and e-coat must be
penetrated to obtain continuity). Connect the other
test lead to the outer crimp on the antenna coaxial
cable connector.
(2) The resistance should be less than (1) ohm.
(3) If the resistance is more than (1) ohm, clean
and/or tighten the antenna base to the fender mount-
ing hardware.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove glove box from instrument panel,
(Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE
BOX - REMOVAL).
Fig. 1 Antenna Test Points
8A - 4 AUDIORS
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(11) Connect antenna cable connector to extension
cable.(12) Install glove box to instrument panel.
(13) Connect the battery negative cable.
ANTENNA MODULE - EXPORT
DESCRIPTION
The antenna module is an electromagnetic circuit
component designed to capture and enhance RF
(Radio Frequency) signals in both the AM and FM
broadcast bands. The antenna module is mounted to
the right rear roof rail under the headliner. The mod-
ule is grounded through the mounting bracket and
fastener. The module has a two wire electrical con-
nector that connects to the integral radio antenna,
located on the right rear quarter glass. There is also
an electrical connector for battery voltage and a coax
cable connector.
OPERATION
The antenna module receives both AM and FM
radio signals supplied by the side window integral
radio antenna system and selectively amplifies them.
The amplified signal is then sent through the body
length coax cable to the radio input.
DIAGNOSIS AND TESTING - ANTENNA MODULE - EXPORT
CONDITION POSSIBLE CAUSES CORRECTION
NO AM RECEPTION,
WEAK FM RECEPTION1. Antenna module to antenna
connector open or disconnected.1. Repair open, reconnect
antenna module connector to
glass mounted antenna.
2. Coax open or disconnected. 2. Repair open, reconnect coax.
3. No battery power at antenna
module.3. Check fuse. if okay, repair
open in battery voltage circuit.
NO AM OR FM
RECEPTION1. Coax disconnected at radio. 1. Reconnect coax.
2. Coax shorted to ground. 2. Repair or Replace coax
WEAK OR NO AM/FM
RECEPTION1. Antenna Module faulty. 1. Substitute known good
module. If reception improves,
Antenna Module was faulty.
Fig. 4 Antenna Cap Nut
1 - CAP NUT
2 - ANTENNA ADAPTER
3 - TOOL
8A - 6 AUDIORS
ANTENNA BODY AND CABLE (Continued)
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REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Lower headliner as necessary to access
antenna module (Fig. 5).
(3) Disconnect antenna coax cable lead and electri-
cal harness connector from antenna module.
(4) Disconnect the antenna module connector from
the quarter glass.
(5) Remove the mounting screw and the antenna
module.
INSTALLATION
(1) Install the antenna module and the mounting
fastener.
(2) Connect the antenna connector to the quarter
glass.
(3) Connect the antenna lead and electrical con-
nector to the antenna module.
(4) Raise and install headliner.
(5) Connect the battery negative cable.
CD CHANGER
DESCRIPTION
The 4 Disc In-Dash CD Changer (if equipped) is
located in the instrument panel below the radio. The
remote changer does not use a cartridge or magazine
for the CD's. Up to 4 CD's can be directly loaded into
this unit.
OPERATION
Due to its compact design, the CD changer can
carry out only one operation at a time. For example,you can not load a new disc while playing another at
the same time. Each operation happens sequentially.
The radio unit provides control over all features of
the CD changer with the exception of the CD load
and eject functions, which are controlled by buttons
located on the front of the CD changer. All features
you would expect, such as Disc Up/Down, Track
Up/Down, Random and Scan are controlled by the
radio, which also displays all relevant CD changer
information on the radio display.
The CD changer contains a Load/Eject button and
an indicator LED for each of the four disc positions
as well as an illuminated disc opening. The individ-
ual LED indicates whether a CD is currently loaded
in that particular chamber of the CD changer. Press-
ing the individual Load/Eject button for a particular
chamber will eject a disc currently present in that
chamber. If the chamber is currently empty, actuat-
ing the Load/Eject button will position that chamber
to receive and load a new disc in that chamber.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove screws holding CD changer.
(3) Disconnect the wire connector from the back of
the CD changer.
(4) Remove the CD changer from the vehicle (Fig.
6).
INSTALLATION
(1) Reconnect the wire connector to the CD
changer.
(2) Insert the CD changer into the instrument
panel.
Fig. 5 ANTENNA MODULE
1 - ANTENNA MODULE
2 - ANTENNA MODULE CONNECTOR
Fig. 6 CD - CHANGER
1 - CD-CHANGER
2 - POWER OUTLET
RSAUDIO8A-7
ANTENNA MODULE - EXPORT (Continued)
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