radiator CHRYSLER CARAVAN 2005 User Guide

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)

CLEANING
Drain cooling system and refill with clean water.
Refer to drain and fill procedures in this section. Run
engine with radiator cap installed until upper radia-
tor hose is hot. Stop engine and drain water from
system. If water is dirty; fill, run, and drain system
again, until water runs clear. Refill cooling system
with a 50/50 mixture of the recommended ethylene
glycol and distilled water (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - DESCRIPTION).
INSPECTION
After performing a cleaning/flush procedure,
inspect all hoses, clamps and connections for deterio-
ration and leaks. Inspect radiator and heater core for
leaks.
Fig. 1 Temperature Gauge Indications
7 - 18 ENGINERS
ENGINE (Continued)

COOLANT
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.
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 and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant.CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
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 -46ÉC (-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 (Special Tool 8286)(Refer to 7 -
COOLING - SPECIAL TOOLS) 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.
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
RSENGINE7-19

COOLANT RECOVERY
CONTAINER
DESCRIPTION
The coolant recovery/reserve system container is
mounted in the engine compartment (Fig. 2). The
container is made of plastic.
OPERATION
The coolant recovery system works with the radia-
tor pressure cap to use thermal expansion and con-
traction of the coolant 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 reserve coolant to cover
deaeration, evaporation, or boiling losses.
DIAGNOSIS AND TESTING - COOLANT
RECOVERY SYSTEM
The cooling system is closed and designed to main-
tain coolant level to the top of the radiator.
(1) With the engineoffand cooling systemnot
under pressure, drain several ounces of coolant from
the radiator draincock while observing the coolant
recovery container. Coolant level in the container
should drop.
(2) Remove the radiator pressure cap. The coolant
level should be full to the top radiator neck. If not,
and the coolant level in the container is at or above
the MIN mark, there is an air leak in the coolant
recovery system.
(3) Check hose and hose connections to the con-
tainer, radiator filler neck or the pressure cap seal to
the radiator filler neck for leaks.
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the lower attaching screws (Fig. 2).
(3) Lower the vehicle.
(4) Remove the upper attaching screw (Fig. 2).
(5) Disconnect recovery hose from container (Fig.
2).
(6) Remove the recovery container.
INSTALLATION
(1) Connect the recovery hose to container (Fig. 2).
(2) Position the recovery container on the frame
rail (Fig. 2).
(3) Install the upper attaching screw and tighten
to 7 N´m (60 in. lbs.) (Fig. 2).
(4) Raise the vehicle on hoist.
(5) Install the lower attaching screws and tighten
to 8.5 N´m (75 in. lbs.) (Fig. 2).
(6) Lower the vehicle.(7) Add coolant to container as necessary. (Refer to
7 - COOLING - STANDARD PROCEDURE)
ENGINE BLOCK HEATER
DESCRIPTION
The engine block heater is available as an optional
accessory on all models. The heater is operated by
ordinary house current (110 Volt A.C.) through a
power cord located behind the radiator grille. This
provides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures. The heater is mounted in a core
hole (in place of a core hole plug) in the engine block,
with the heating element immersed in coolant.
OPERATION
The block heater element is submerged in the cool-
ing system's coolant. When electrical power (110 volt
A.C.) is applied to the element, it creates heat. This
heat is transferred to the engine coolant. This pro-
vides easier engine starting and faster warm-up
when vehicle is operated in areas having extremely
low temperatures.
Fig. 2 Coolant Recovery Container
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
7 - 20 ENGINERS

DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER TESTING
If unit does not operate, trouble can be in either
the power cord or the heater element. Test power
cord for continuity with a 110-volt voltmeter or 110-
volt test light; test heater element continuity with an
ohmmeter or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
(2) Disconnect the power cord plug from heater.
(3) Loosen screw in center of heater. Remove the
heater assembly.
INSTALLATION
(1) Clean block core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Install power cord plug to heater.
(5) Fill cooling system with coolant to the proper
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
ENGINE COOLANT
TEMPERATURE SENSOR - 2.4L
DESCRIPTION
The engine coolant temperature sensor threads
into the top of the thermostat housing (Fig. 3). New
sensors have sealant applied to the threads.
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Drain the cooling system below thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
(2) Disconnect coolant temperature sensor electri-
cal connector.
(3) Remove coolant temperature sensor (Fig. 3).
INSTALLATION
(1) Install coolant temperature sensor (Fig. 3).
Tighten sensor to 7 N´m (60 in. lbs.).
(2) Connect electrical connector to sensor.
(3) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
ENGINE COOLANT
TEMPERATURE SENSOR -
3.3/3.8L
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage on lower intake manifold near
the thermostat (Fig. 6). New sensors have sealant
applied to the threads.
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
Fig. 3 Engine Coolant Temperature Sensor - 2.4L
1 - MAP SENSOR
2 - COOLANT TEMPERATURE SENSOR
RSENGINE7-21
ENGINE BLOCK HEATER (Continued)

INSTALLATION
(1) Install engine coolant temperature sensor (Fig.
6). Tighten sensor to 7 N´m (60 in. lbs.).
(2) Connect electrical connector to sensor (Fig. 6).
(3) Install ignition coil bracket (Fig. 5).
(4) Install ignition coil (Fig. 5).
(5) Install power steering reservoir (Fig. 4).
(6) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
The engine cooling thermostats are a wax pellet
driven, reverse poppet choke type. The thermostat is
mounted in a housing on the coolant outlet of the
engine (Fig. 8) or (Fig. 10).
OPERATION
The engine cooling thermostat is a wax pellet
driven, reverse poppet choke type. The thermostat is
designed to provide the fastest warm up possible by
preventing leakage through it and to guarantee a
minimum engine operating temperature of 88 to
93ÉC (192 to 199ÉF). The thermostat also will auto-
matically reach wide open so it will 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 radiator, fan, and ambient temperature, not the
thermostat.
The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed. When heated coolant
reaches a predetermined temperature, the wax
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
DIAGNOSIS AND TESTING - ENGINE COOLANT
THERMOSTAT
The thermostat is operated by a wax filled cham-
ber (pellet) which is sealed. When heated coolant
reaches a predetermined temperature the wax pellet
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Coolant leakage into the pellet will cause a thermo-
stat to fail open. Do not attempt to free up a thermo-
stat with a screwdriver.
Thermostat diagnostics is included in powertrain
control module's (PCM) programing for on-board
diagnosis. The malfunction indicator light (MIL) will
illuminate and a diagnostic trouble code (DTC) will
be set when an ªopen too soonº condition occurs. Do
not change a thermostat for lack of heater perfor-
mance or temperature gauge position, unless a DTC
is present. For other probable causes, (Refer to 7 -
COOLING/ENGINE - DIAGNOSIS AND TESTING).
Thermostat failing shut is the normal long term
mode of failure, and normally, only on high mileage
vehicles. The temperature gauge will indicate this
(Refer to 7 - COOLING/ENGINE - DIAGNOSIS AND
TESTING).Fig. 6 Engine Coolant Temperature Sensor
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
RSENGINE7-23
ENGINE COOLANT TEMPERATURE SENSOR - 3.3/3.8L (Continued)

ENGINE COOLANT
THERMOSTAT - 2.4L
REMOVAL
(1) Drain cooling system below the thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
(2) Remove radiator upper hose from the coolant
outlet housing (Fig. 7).
(3) Remove coolant outlet housing bolts and hous-
ing (Fig. 8).
(4) Remove thermostat. Discard gasket and clean
both gasket sealing surfaces.
INSTALLATION
(1) Place a new gasket (dipped in clean water) on
the coolant outlet connector surface. Position thermo-
stat with air bleed at the 12 o'clock position in ther-
mostat housing (Fig. 8).
(2) Position the coolant outlet connector and gas-
ket over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Position outlet connector to thermostat housing
and install bolts (Fig. 8). Tighten bolts to 28 N´m
(250 in. lbs.).
(4) Install the radiator upper hose to coolant outlet
housing (Fig. 7).
(5) Refill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
ENGINE COOLANT
THERMOSTAT - 3.3/3.8L
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. (Refer to 7 - COOLING - STANDARD
PROCEDURE)
(2) Remove radiator upper hose from coolant outlet
connector (Fig. 9).
Fig. 7 RADIATOR HOSES TO ENGINE - 2.4L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 8 Thermostat and Outlet Connector - 2.4L
Engine
1 - THERMOSTAT
2 - GASKET
3 - COOLANT OUTLET CONNECTOR
4 - BOLT
Fig. 9 RADIATOR HOSES TO ENGINE - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
7 - 24 ENGINERS

(3) Remove coolant outlet connector bolts and con-
nector (Fig. 10).
(4) Remove thermostat from outlet connector.
(5) Discard gasket and clean both gasket sealing
surfaces.
INSTALLATION
(1) To ensure proper seating of replacement ther-
mostat, carefully remove the bulged metal from the
wall of the outlet connector recess that was created
during the staking procedure that held the OEM
thermostat in place (Fig. 11). It is not necessary to
restake the replacement thermostat into the connec-
tor.
(2) Position thermostat to coolant outlet connector.
Align the two locating notches on thermostat to the
connector (Fig. 12). This position will ensure proper
location of the thermostat air bleed.
(3) Position a new gasket over the thermostat and
connector making sure thermostat is in proper posi-
tion and in the recess provided.
(4) Install thermostat and connector assembly to
the intake manifold (Fig. 10). Tighten bolts to 28
N´m (250 in. lbs.).
(5) Install the radiator upper hose to coolant outlet
connector (Fig. 9).
(6) Refill the cooling system to the proper level.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
Fig. 10 THERMOSTAT - 3.3/3.8L ENGINE
1 - COOLANT OUTLET CONNECTOR
2 - BOLT
3 - THERMOSTAT
4 - GASKET
Fig. 11 Connector Staking Material Removal
1-STAKE
2 - OUTLET CONNECTOR
Fig. 12 Thermostat Position In Outlet Connector
1 - LOCATING NOTCH
2 - THERMOSTAT
3 - COOLANT OUTLET CONNECTOR
RSENGINE7-25
ENGINE COOLANT THERMOSTAT - 3.3/3.8L (Continued)

RADIATOR
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 - STANDARD PROCEDURE)
(4) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(5) Disconnect coolant reserve/recovery hose.
(6) Remove vapor purge solenoid from mounting
bracket.
(7) Disconnect upper and lower hoses from the
radiator (Fig. 13) or (Fig. 14).
(8) Lift the A/C condenser straight up to disengage
the lower A/C condenser mounting brackets from the
radiator. (Fig. 15). Separate the condenser from the
radiator by lifting upward to disengage from lower
mounts (Fig. 15). Allow the condenser to rest in front
of radiator.(9) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
Fig. 13 Radiator Hoses to Radiator - 2.4L
1 - UPPER HOSE
2 - LOWER HOSE
3 - HOSE SUPPORT CLIP
Fig. 14 Radiator Hoses to Radiator - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 15 A/C Condenser ± 2.4L/3.3L/3.8L Engines
1 - A/C CONDENSER
2 - AUTO TRANS COOLER TAPPING BLOCK
3 - UPPER CONDENSER MOUNTING BRACKET (2)
4 - RADIATOR
5 - LOWER CONDENSER MOUNTING BRACKET (2)
7 - 26 ENGINERS

INSTALLATION
(1)Be sure the air seal is in position before
radiator is installed.Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the
radiator lower mounts and ingage upper mounting
tabs. (Fig. 15).
(3) Install the radiator upper and lower hoses (Fig.
13) or (Fig. 14).
(4) Connect the coolant reserve/recovery hose.
(5) Connect the vapor purge solenoid to the mount-
ing bracket.
(6) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(7) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
(9) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Using a screwdriver, open the draincock by
turning it counterclockwise until it stops.
(3) Pull the draincock from the radiator tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
CAUTION: Do not overtighten. The head of the
draincock may break off.
(3) Using a screwdriver, tighten the draincock by
turning clockwise until it stops.
(4) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system pressure cap is located on the
radiator. The cap construction includes; stainless
steel swivel top, rubber seals, and retainer, main
spring, and a spring loaded valve (Fig. 16).
OPERATION
The cooling system is equipped with a pressure cap
that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing the coolant to return to cooling
system from coolant reserve system tank by vacuum
through a connecting hose.If valve is stuck shut,
or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 16) and inspect cool-
ant recovery hose routing, to ensure proper
sealing when boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.
If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant
and eventual overheating due to low coolant
level in radiator and engine.
Fig. 16 Cooling System 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 - RADIATOR
8 - FILLER NECK
RSENGINE7-27
RADIATOR (Continued)