2004 CHRYSLER VOYAGER heater

NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gel-
ling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and fol-
low the cold weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm up perfor-
mance.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC.
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Hous-
ing (front) and the Differential Carrier (rear).
The recommended lubricant for the Overrunning
Clutch Housing is MopartATF+4. The recommended
lubricant for the Differential Carrier is Mopart
80W-90 Gear and Axle Lubricant.
DESCRIPTION - AWD POWER TRANSFER UNIT
FLUID
The recommended lubricant for the AWD Power
Transfer Unit is MopartGear and Axle Lubricant
80W-90.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
Engine Oil* - 2.5 L (Diesel) 6.0 L (6.3 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with Auxiliary
Heater13.8 L (14.6 qts.)
Cooling System** - 3.3/3.8
L without Auxiliary Heater12.6 L (13.4 qts.)
Cooling System** - 3.3/3.8
L with Auxiliary Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-Speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
0 - 6 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

OPERATION
OPERATION - COOLING SYSTEM
The engine cooling systems primary purpose is to
maintain engine temperature in a range that will
provide satisfactory engine performance and emission
levels under all expected driving conditions. It also
provides hot water (coolant) for heater performance
and cooling for automatic transmission oil. It does
this by transferring heat from engine metal to cool-
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.
²When engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²When engine is warm: thermostat is open, cool-
ing system has bypass flow and coolant flow through
radiator.
Coolant flow circuits for the 2.4L and 3.3/3.8L
engines are shown in (Fig. 2).
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. 3) to compress the
hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAK TEST
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.
Fig. 2 Cooling System Flow
1 - HEATER - REAR (3.3/3.8L OPTIONAL EQUIPMENT) 6 - WATER PUMP
2 - HEATER - FRONT 7 - RADIATOR
3 - ENGINE 8 - COOLANT RECOVERY/RESERVE CONTAINER
4 - THERMOSTAT 9 - COOLANT FLOW - PRESSURE CAP VACUUM
5 - ENGINE OIL COOLER (3.3/3.8L OPTIONAL EQUIPMENT) 10 - COOLANT FLOW - PRESSURE CAP RELIEF
7 - 2 COOLINGRS
COOLING (Continued)

With engine not running, remove radiator pressure
cap and wipe the radiator filler neck sealing seat
clean. The radiator should be full.
Attach the Cooling System Tester 7700 or equiva-
lent to the radiator, as shown in (Fig. 4) and apply
104 kPa (15 psi) pressure. If the pressure drops more
than 13.8 kPa (2 psi) in 2 minutes, inspect all points
for external leaks.
All radiator and heater hoses should be shaken
while at 104 kPa (15 psi), since some leaks occur only
while driving due to engine movement.
If there are no external leaks, after the gauge dial
shows a drop in pressure, detach the tester. Start
engine and run until the thermostat opens, allowing
the coolant to expand. Reattach the cooling systemtester. If the needle on the dial fluctuates it indicates
a combustion leak, usually a head gasket leak.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL
BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP,
BY CONTINUOUS ENGINE OPERATION, MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, raise
the engine rpm a few times. If an abnormal amount
of coolant or steam emits from the tailpipe, it may
indicate a coolant leak caused by a faulty head gas-
ket, cracked engine block, or cracked cylinder head.
There may be internal leaks that can be deter-
mined by removing the oil dipstick. If water globules
appear intermixed with the oil it will indicate an
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
DIAGNOSIS AND TESTING - COOLING SYSTEM
FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use one of the following proce-
dures:
PREFERRED METHOD
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP OR ANY HOSE WITH THE
SYSTEM HOT AND UNDER PRESSURE BECAUSE
SERIOUS BURNS FROM COOLANT CAN OCCUR.
²Remove pressure cap when engine is cold.
Remove small amount of coolant. Idle engine until
thermostat opens. You should observe coolant flow
while looking down the filler neck. Once flow is
detected install the pressure cap. Replace removed
coolant into coolant recovery container.
ALTERNATIVE METHOD
²If engine is cold, idle engine until normal oper-
ating temperature is reached. Feel the upper radiator
hose. If it is hot, coolant is circulating.
DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
²High reading shown on the temperature gauge.
²Loss of coolant flow through the heater core.
Fig. 3 Hose Clamp Tool
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 4 Pressure Testing
RSCOOLING7-3
COOLING (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DIAGNOSIS AND TESTING - ENGINE
COOLING SYSTEM....................14
CLEANING............................18
INSPECTION..........................18
COOLANT
DESCRIPTION - ENGINE COOLANT.........19
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING.............19
STANDARD PROCEDURE - COOLANT
SERVICE............................19
COOLANT RECOVERY CONTAINER
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING - COOLANT
RECOVERY SYSTEM..................20
REMOVAL.............................20
INSTALLATION.........................20
ENGINE BLOCK HEATER
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER TESTING.....................20
REMOVAL.............................20
INSTALLATION.........................20
ENGINE COOLANT TEMPERATURE SENSOR -
2.4L
DESCRIPTION.........................21
REMOVAL.............................21
INSTALLATION.........................21
ENGINE COOLANT TEMPERATURE SENSOR -
3.3/3.8L
DESCRIPTION.........................21
REMOVAL.............................21
INSTALLATION.........................22
ENGINE COOLANT THERMOSTAT
DESCRIPTION.........................22
OPERATION...........................22
DIAGNOSIS AND TESTING - ENGINE
COOLANT THERMOSTAT...............23
ENGINE COOLANT THERMOSTAT - 2.4L
REMOVAL.............................23
INSTALLATION.........................23
ENGINE COOLANT THERMOSTAT - 3.3/3.8L
REMOVAL.............................23
INSTALLATION.........................24
RADIATOR
REMOVAL.............................25INSTALLATION.........................25
RADIATOR DRAINCOCK
REMOVAL.............................26
INSTALLATION.........................26
RADIATOR PRESSURE CAP
DESCRIPTION.........................26
OPERATION...........................27
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP TESTING.......27
DIAGNOSIS AND TESTING - RADIATOR
CAP TO FILLER NECK SEAL.............27
CLEANING............................28
INSPECTION..........................28
RADIATOR FAN
DESCRIPTION.........................28
OPERATION...........................29
DIAGNOSIS AND TESTING - RADIATOR FAN
MOTOR .............................29
REMOVAL.............................30
INSTALLATION.........................30
RADIATOR FAN RELAY
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................30
WATER PUMP - 2.4L
DESCRIPTION.........................31
REMOVAL.............................31
CLEANING............................32
INSPECTION..........................32
INSTALLATION.........................32
WATER PUMP - 3.3/3.8L
DESCRIPTION.........................33
REMOVAL.............................33
CLEANING............................34
INSPECTION..........................34
INSTALLATION.........................34
WATER PUMP INLET TUBE - 2.4L
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................35
WATER PUMP INLET TUBE - 3.3/3.8L
REMOVAL.............................36
INSTALLATION.........................36
RSENGINE7-13

ENGINE
DIAGNOSIS AND TESTING - ENGINE COOLING
SYSTEM
Establish what driving condition caused the cooling
system complaint. The problem may be caused by an
abnormal load on the system such as the following:
prolonged idle, very high ambient temperature, slight
tail wind at idle, slow traffic speed, traffic jam, high
speed, steep grade.
DRIVING TECHNIQUES
To avoid overheating the cooling system:
(1) Idle with A/C off when temperature gauge is at
end of normal range.
(2) Do not increase engine speed for more air flow
and coolant flow because the electric motor fan sys-
tems are not responsive to engine RPM. The added
cooling from higher coolant flow rate is more than
offset by increased heat rejection (engine heat added
to coolant).
TRAILER TOWING
Consult the owner's manual under Trailer Towing
and do not exceed specified limits.
VISUAL INSPECTION
If the cooling system problem is not caused by a
driving condition, perform a visual inspection to
determine if there was a recent service or accident
repair, including the following:
²Loose/damaged water pump drive belt
²Incorrect cooling system refilling (trapped air or
low level)
²Brakes possibly dragging
²Damaged hoses
²Loose/damaged hose clamps
²Damaged/incorrect engine thermostat
²Damaged cooling fan motor, fan blade and fan
shroud
²Damaged head gasket
²Damaged water pump
²Damaged radiator
²Damaged coolant recovery system
²Damaged heater core
²Open/shorted electrical circuits
If the visual inspection reveals none of the above
as cause for a cooling system complaint, refer to the
following diagnostic charts.
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
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 RESERVE/
OVERFLOW TANK.1. Pressure relief valve in radiator
cap is defective, or was not
properly seated.1. Check condition of radiator cap
and cap seal. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING) Replace cap as
necessary.
2. Incorrect cap was installed. 2. Replace cap as necessary.
3. Incorrect coolant mixture. 3. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE IS
READING HIGH OR HOT.1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING)
7 - 14 ENGINERS

CONDITION POSSIBLE CAUSES CORRECTION
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY NOT BE
READING HIGH.1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture too concentrated or
too diluted.2. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
3. Incorrect cooling system
pressure cap.3. Install correct pressure cap.
HOSE(S) COLLAPSE AS ENGINE
COOLS DOWN.1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
recovery system.1. (a) Pressure cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING)
Replace as necessary.
(b) Hose between the radiator and
overflow container is plugged or
pinched. Clean and repair as
necessary.
(c) Vent at coolant reserve/overflow
container is plugged. Clean vent
and repair as necessary.
(d) Reserve/overflow container is
internally blocked. Clean and repair
as necessary.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED).1. Radiator and/or A/C condenser is
restricted, obstructed, or dirty
(insects, leaves, etc.).1. Remove restriction and/or clean
as necessary.
2. Electrical radiator fan not
operating when A/C is operated.2. For test procedure (Refer to
appropriate Diagnostic Information).
Repair as necessary.
3. Engine is overheating (heat may
be transferred from radiator to A/C
condenser). High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components.3. Correct overheating condition.
4. All models are equipped with air
seals at the radiator and/or A/C
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.4. Check for missing or damaged air
seals and repair as necessary.
INADEQUATE HEATER
PERFORMANCE.1. Check for a Diagnostic trouble
code (DTC).1. For procedures, (Refer to
appropriate Diagnostic Information).
Repair as necessary.
2. Coolant level low. 2. (Refer to 7 - COOLING -
STANDARD PROCEDURE) Repair
as necessary.
RSENGINE7-15
ENGINE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
3. Obstructions in heater hose
fitting at engine or at heater core.3. Remove heater hoses at both
ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping
coolant to heater core.5. 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. Replace
components as necessary.
6. Air trapped in heater core. 6. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING -
COOLING SYSTEM DEAERATION)
HEAT ODOR 1. Various heat shields are used at
certain driveline components. One
or more of these shields may be
missing.1. Locate missing shields and
replace or repair as necessary.
2. Temperature gauge reading
above the normal range.2. Refer to Gauge Is Reading High
in Temperature Gauge Indicatication
Diagnosis Chart.
3. Radiator fan operating
incorrectly.3. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - OPERATION)
Repair as necessary.
4. Undercoating been applied to an
unnecessary component.4. Clean undercoating as necessary.
5. Engine may be running rich,
causing the catalytic converter to
overheat5. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
POOR DRIVEABILITY
(THERMOSTAT POSSIBLY STUCK
OPEN). GAUGE MAY BE READING
LOW.1. The engine thermostat must be
operating correctly for proper
driveability, clean vehicle emissions,
and the prevention of sludge
buildup in the engine oil. Check for
a diagnostic trouble code.1. (Refer to Appropriate Diagnostic
Information) Replace thermostat, if
necessary.
STEAM IS COMING FROM FRONT
OF VEHICLE NEAR GRILL AREA
WHEN WEATHER IS WET,
ENGINE WARMED UP AND
RUNNING WITH VEHICLE
STATIONARY, OR JUST SHUT
OFF. TEMPERATURE GAUGE IS
NORMAL.1. During wet weather, moisture
(snow, ice, rain, or condensation)
on the radiator will evaporate when
the thermostat opens. The
thermostat opening allows heated
coolant into the radiator. When the
moisture contacts the hot radiator,
steam may be emitted. This usually
occurs in cold weather with no fan
or air flow to blow it away.1. Occasional steam emitting from
this area is normal. No repair is
necessary.
7 - 16 ENGINERS
ENGINE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.1. Check the freeze point of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as necessary.
COOLANT LEVEL CHANGES IN
COOLANT BOTTLE.
TEMPERATURE GAUGE IS IN
NORMAL RANGE.1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
The coolant level will also drop as
the system removes air from a
recent filling.1. A normal condition. No repair is
necessary.
Refer to (Fig. 1) when using the TEMPERATURE
GAUGE INDICATION DIAGNOSIS CHART.
TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC).1. Normal reaction to fan and/or
thermostat cycle (Fig. 1 ),
Examples B and C. During cold
weather operation with the heater
blower in the high position, the
gauge reading may drop slightly
(Fig. 1 ), Example D. Fluctuation is
also influenced by outside
temperature and heavy loads (Fig.
1 ), Example E.1. A normal condition. No correction
is necessary.
2. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
(Fig. 1 ), Example F.2. A normal condition. No correction
is necessary. Gauge reading should
return to normal range (Fig. 1 ),
Example A, after vehicle is driven.
3. Gauge reading high after
restarting a warmed-up (hot)
engine.3. A normal condition. No correction
is necessary. The gauge should
return to normal range (Fig. 1 ),
Example A, after a few minutes of
engine operation.
4. Temperature gauge or engine
coolant temperature sensor
defective or shorted. Also, corroded
or loose wiring in the electrical
circuit.4. Check operation of gauge or
engine coolant temperature sensor
and repair, if necessary.
RSENGINE7-17
ENGINE (Continued)