water pump CHRYSLER VOYAGER 1996 User Guide

ACCESSORY DRIVE BELTSÐ3.0L
GENERATOR/POWER STEERING PUMP BELT
REMOVAL/INSTALLATION
The Poly-V generator/power steering pump belt is
provided with a dynamic tensioner (Fig. 34) to main-
tain proper belt tension. To remove or install this
belt, apply force in a clockwise direction to the ten-
sioner pulley bolt (Fig. 34).
AIR CONDITIONING BELT
REMOVAL
To remove the air conditioning compressor drive
belt, first loosen the idler pulley lock nut, then turn
the adjusting screw to lower the idler pulley (Fig.
35).
INSTALLATION/ADJUSTMENT
To adjust the air conditioning drive belt,
loosen the idler pulley lock nut (Fig. 35) and adjust
belt tension by tightening adjusting screw. Refer toProper Belt Tension and Belt Tension Chart in this
Section for procedure. Tighten pulley lock nut to 54
N´m (40 ft. lbs.) after adjustment.
ACCESSORY DRIVE BELTÐ3.3/3.8L
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING
COMPRESSOR AND WATER PUMP DRIVE BELT
The Poly-V Drive belt is provided with a dynamic
tensioner (Fig. 36) to maintain proper belt tension.
To remove or install this belt.
(1) Raise vehicle on hoist.
(2) Remove right front splash shield.
(3) Release tension by rotating the tensioner
clockwise (Fig. 36).
(4) Reverse above procedure to install.
CLEANING AND INSPECTION
WATER PUMP
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; if the seal is leaking, this will be
evident by traces of thick deposits of greenish-brown
dried glycol running down the pump body and com-
ponents below. A thin black stain below pump weep
hole is considered normal operation.
(3) Impeller rubs inside of chain case cover
3.3/3.8L or cylinder block 2.4L engines.
(4) Excessively loose or rough turning bearing.
Fig. 34 Release Belt TensionerÐ3.0L
Fig. 35 Air Conditioning Drive BeltÐ3.0L Engine
Fig. 36 Accessory Drive BeltÐ3.3/3.8L Engines
7 - 24 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

NOTE: It is normal for the water pump to weep a
small amount of coolant from the weep hole (black
stain on water pump body). Do not replace the
water pump if this condition exists. Replace the
water pump if a heavy deposit or a steady flow of
green/brown engine coolant is evident on water
pump body from the weep hole (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
ACCESSORY DRIVE BELT
When inspecting serpentine drive belts, small
cracks that run across the ribbed surface of the belt
from rib to rib (Fig. 37), are considered normal. these
are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal.
Any belt with cracks running along the rib must be
replaced (Fig. 37). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
RADIATOR PRESSURE CAP
INSPECTION
Hold the cap in hand,right side up. The vent
valve at the bottom of the cap should open. If the
rubber gasket has swollen and prevents the valve
from opening, replace the cap.
Hold the cleaned cap in handupside down.If any
light shows between vent valve and rubber gasket,
replace cap.Do not use a replacement cap that
has a spring to hold the vent shut.
Replacement cap must be of the type designed for
coolant reserve system with a completely sealed dia-
phragm spring, and rubber gasket to seal to fillerneck top surface. This design assures coolant return
to radiator.
COOLING SYSTEM CLEANING
Drain cooling system (see:Cooling System
Draining) and refill with clean water (see:Cooling
System Refilling). Run engine with radiator cap
installed until upper radiator hose is hot. Stop
engine and drain water from system. If water is
dirty; fill, run, and drain system again, until water
runs clear.
REVERSE FLUSHING THE RADIATOR
Drain cooling system and remove radiator hoses
from engine. Install suitable flushing gun in radiator
lower hose. Fill radiator with clean water and turn
on air in short blasts.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedure until water runs
clear.
REVERSE FLUSHING THE ENGINE
Drain radiator (see:Draining Cooling System)
and remove hoses from radiator. Remove engine ther-
mostat and reinstall thermostat housing. Install suit-
able flushing gun to thermostat housing hose. Turn
on water, and when engine is filled, turn on air, but
no higher than 138 kPa (20 psi) in short blasts. Allow
engine to fill between blasts of air. Continue this pro-
cedure until water runs clean. Reinstall thermostat
using a new housing gasket. Fill cooling system (See
Refilling).
CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor-
rosion products are carried to the radiator and depos-
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be
removed with a two part cleaner (oxalic acid and
neutralizer) available in auto parts outlets. Follow
manufacturers directions for use.
ADJUSTMENTS
PROPER BELT TENSION
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of a Burroughs
gauge Special Tool C-4162. Because of space limita-
tions in the engine compartment, the use of the
gauge may be restricted. Raise the vehicle on a hoist
Fig. 37 Serpentine Drive Belt Wear Patterns
NSCOOLING SYSTEM 7 - 25
CLEANING AND INSPECTION (Continued)

and the remove the splash shield to gain access to
the drive belts.
BELT TENSION GAUGE METHOD
Use belt tensioning Special Tool Kit C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V
belt is not to be used on the V-belt. These gauges
are not interchangeable.
²For conventional V-belts affix the Burroughs
gauge (Special Tool C-4162) to the belt. Adjust the
belt tension for New or Used belt as prescribed in the
Belt Tension Chart.
²For a Poly-V belt affix the Poly-V Burroughs
gauge to the belt and then apply specified tension to
the belt as prescribed in the Belt Tension Chart
Adjust belt tension for aNeworUsedbelt as pre-
scribed in the Belt Tension Chart.
BELT TENSION CHARTSPECIFICATIONS
COOLING SYSTEM CAPACITY
TORQUE CHART
DESCRIPTION TORQUE
Thermostat Housing
BoltsÐ2.4L & 3.3/3.8L......28N´m(250 in. lbs.)
BoltsÐ3.0L...............12N´m(105 in. lbs.)
Water Pump Mounting
BoltsÐ2.4L & 3.3/3.8L......12N´m(250 in. lbs.)
BoltsÐ3.0L...............27N´m(240 in. lbs.)
Water Pump Inlet Tube
BoltsÐ2.4L...............12N´m(250 in. lbs.)
BoltsÐ3.0L................11N´m(94in.lbs.)
Water Pump Pulley
BoltsÐ3.3/3.8L............28N´m(250 in. lbs.)
Transaxle Oil Cooler Hose
ClampsÐAll Engines.........2N´m(18in.lbs.)
Radiator Mounting Upper Bracket
NutÐAll Engines..........12N´m(105 in. lbs.)
SPECIAL TOOLS
COOLING
ACCESSORY DRIVE
BELTGAUGE
2.4L ENGINE
A/C COMPRESSOR /
GENERATORNEW 190 LB.
USED 115 LB.
POWER STEERING NEW 140 LB.
USED 90 LB.
3.0L ENGINE
A/C COMPRESSOR NEW 150 LB.
USED 80 LB.
GENERATOR / POWER
STEERINGDYNAMIC TENSIONER
3.3/3.8L ENGINES
A/C COMPRESSOR DYNAMIC TENSIONER
GENERATOR / WATER
PUMP / POWER
STEERINGDYNAMIC TENSIONER
Engine Standard Duty Trailer Tow or
Heavy Duty
Front
HeaterRear
HeaterFront
HeaterRear
Heater
2.4L 10.6
liters*
(11.23
qts.)*N/A N/A N/A
3.0L 12.3
liters*
(13.0
qts.)*N/A N/A 15.0
liters*
(15.9
qts.)*
3.3/3.8L 12.5
liters*15.26
liters*12.5
liters*15.26
liters*
(13.23
qts.)*(16.13
qts.)*(13.23
qts.)*(16.13
qts)*
*Includes Heater and Coolant Recovery Tank Filled to
Max Level.
Belt Tension Gauge C-4162
7 - 26 COOLING SYSTEMNS
ADJUSTMENTS (Continued)

COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
COOLANT PRESSURE BOTTLE............ 1
COOLING SYSTEM Ð 2.0L GASOLINE...... 1
COOLING SYSTEM Ð 2.5L VM DIESEL..... 1
LOW COOLANT LEVEL SENSOR........... 1
RADIATOR............................ 2
DESCRIPTION AND OPERATION
AUTOMATIC BELT TENSIONER............ 6
BELT TENSION......................... 5
COOLANT PERFORMANCE............... 5
PRESSURE/VENT CAP................... 4
THERMOSTAT OPERATION............... 4
THERMOSTAT......................... 6
WATER PUMP......................... 3
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT........... 7
DRAINING COOLING SYSTEM............. 7
REFILLING COOLING SYSTEM............ 7
REMOVAL AND INSTALLATION
ENGINE THERMOSTATÐ 2.0L GASOLINE . . . 9GENERATOR/POWER STEERING BELT Ð 2.5L
VM DIESEL......................... 10
RADIATOR Ð 2.5L VM DIESEL........... 9
THERMOSTAT Ð 2.5L VM DIESEL......... 9
WATER PUMP BELT Ð 2.5L VM DIESEL . . . 10
WATER PUMP Ð 2.0L GASOLINE......... 7
WATER PUMP Ð 2.5L VM DIESEL........ 8
CLEANING AND INSPECTION
WATER PUMP........................ 10
ADJUSTMENTS
BELT TENSION CHART................. 11
BELT TENSION GAUGE METHOD......... 11
SPECIFICATIONS
COOLING SYSTEM CAPACITY............ 12
TORQUE CHART...................... 12
SPECIAL TOOLS
COOLING............................ 12
GENERAL INFORMATION
COOLING SYSTEM Ð 2.0L GASOLINE
The 2.0L gasoline engine cooling system consists of
an engine cooling module, thermostat, coolant, a
water pump to circulate the coolant. The engine cool-
ing module may consist of a radiator, electric fan
motors, fan, shroud, coolant reserve system, hoses,
clamps, air condition condenser.
²When the Engine is cold: The thermostat is
closed; the cooling system has no flow through the
radiator. The coolant flows through the engine,
heater system and bypass.
²When the Engine is warm: Thermostat is open;
the cooling system has flow through radiator, engine,
heater system and bypass.
COOLING SYSTEM Ð 2.5L VM DIESEL
The cooling system has a radiator, coolant, electric
fan motors, shroud, pressure cap, thermostat, coolant
pressure bottle, hoses, a water pump to circulate the
coolant, to complete the circuit. Coolant flow for the
VM diesel engine is shown in (Fig. 1).
COOLANT PRESSURE BOTTLE
2.5L VM DIESEL
This system works with the pressure cap to use
thermal expansion and contraction of the coolant to
keep the coolant free of trapped air. It provides some
reserve coolant to cover minor leaks and evaporation
or boiling losses. The coolant pressure bottle location
for 2.5L diesel is above the cylinder head cover (Fig.
2).
LOW COOLANT LEVEL SENSOR
The low coolant level sensor checks for low coolant
level in the coolant tank. A signal will be sent from
this sensor to the Body Control Module (BCM). When
the BCM determines low coolant level for 30 contin-
uous seconds, the instrument panel mounted low
coolant level warning lamp will be illuminated. The
sensor is located on the front side of the coolant tank
(Fig. 4). For information, refer to Group 8E, Instru-
ment Panel and Gauges.
If this lamp is illuminated, it indicates the need to
fill the coolant tank and check for leaks.
NS/GSCOOLING SYSTEM 7 - 1

ties to keep the engine satisfactorily cooled (Fig. 5)
and (Fig. 6).
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.
If the plastic tank is damaged, replace the radia-
tor.
DESCRIPTION AND OPERATION
WATER PUMP
2.0L GASOLINE
The water has a diecast aluminum body and hous-
ing with a stamped steel impeller. The water pumpbolts directly to the block (Fig. 7). Cylinder block to
water pump sealing is provided by a rubber O-ring.
The water pump is driven by the timing belt. Refer
to Group 9, Engine section for component removal to
access the water pump.
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
2.5L VM DIESEL
The Diesel engine water pump has an aluminum
body and housing with a stamped steel impeller. The
pump uses an O-ring gasket between body and hous-
ing. The water pump is driven by the accessory drive
belt, and the pump housing is bolted to the cylinder
block (Fig. 9).
NOTE: The water pump on all models can be
replaced without discharging the air conditioning
system.
Fig. 4 Low Coolant Level Sensor
Fig. 5 Cooling Module Ð2.0LGasoline
Fig. 6 Cooling Module ÐVM Diesel
NS/GSCOOLING SYSTEM 7 - 3
GENERAL INFORMATION (Continued)

THERMOSTAT OPERATION
2.5 VM DIESEL
The engine cooling thermostats are wax pellet
driven, reverse poppet choke type. They are designed
to provide the fastest warm up possible by prevent-
ing leakage through them and to guarantee a mini-
mum engine operating temperature (Fig. 10). The
thermostat has a hole to bleed off air in the cooling
system during engine warm up. The thermostat
begins to open at 80É C62É (176É F64É).
PRESSURE/VENT CAP
WARNING: Engine coolant can reach temperatures
of 200É fahrenheit or greater. If the cooling system
is opened with coolant at a high temperature, hot
coolant can be forced out of the system under high
pressures, causing personal injury. Allow system to
cool down prior to removing the pressure cap.
The pressure/vent cap is secured to the coolant
tank neck by a means of a cam lock system. This cap
releases excess pressure at some point within a
range of 90-117 kPa (13- 17 psi) for gasoline engines,
and 110±124 kPa (16±18 psi) for diesel engines. The
actual pressure relief point (in pounds) is labeled on
top of the cap (Fig. 11).
The cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi-
ator cooling capacity. The cap (Fig. 11) contains a
spring-loaded pressure relief valve. This valve opens
when system pressure reaches approximately 103
kPa (15 psi).
When the engine is cooling down, vacuum is
formed within the cooling system. To prevent collapse
of the radiator and coolant hoses from this vacuum, a
vacuum valve is used within the cap. This valve pre-
vents excessive pressure differences from occurring
between the closed cooling system and the atmo-
sphere. If the vacuum valve is stuck shut, the radia-
tor and/or cooling system hoses will collapse on cool-
down.
Fig. 7 Water PumpÐ2.0L Gasoline Engine
Fig. 8 Water PumpÐ2.0L Gasoline Engine
Fig. 9 Water PumpÐ2.5L VM Diesel
Fig. 10 Thermostat and Housing Ð 2.5L VM Diesel
7 - 4 COOLING SYSTEMNS/GS
DESCRIPTION AND OPERATION (Continued)

SERVICE PROCEDURES
ADDING ADDITIONAL COOLANT
2.5L VM DIESEL
Do not remove coolant bottle pressure cap when
the engine is hot. Remove pressure cap and fill cool-
ant bottle between Min and Max lines inside filler
neck. Use only 50/50 mix of ethylene glycol type anti-
freeze and water (Fig. 13). Squeezing radiator hoses
may help purge air from the cooling system.
DRAINING COOLING SYSTEM
2.0L GASOLINE
To drain cooling system move temperature selector
for heater to full heat with engine running.Without
removing radiator pressure cap and with sys-
tem not under pressure,Shut engine off and open
draincock. The coolant reserve tank should empty
first, then remove radiator pressure cap and let the
radiator drain (if not, see Testing Cooling System for
leaks).
2.5L VM DIESEL
The cooling system does not have a radiator
mounted pressure cap. Instead the pressure cap is
mounted on the coolant pressure bottle (Fig. 14).
(1) Shut off engine.
(2) Remove radiator pressure cap.
(3) Open draincock and allow coolant to drain.
REFILLING COOLING SYSTEM
2.0L GASOLINE
Refer to the gasoline engine cooling system infor-
mation in this manual. Cooling system capacity is 6.0
liters (6.34 qts.) which includes the heater and cool-
ant recovery tank.
2.5L VM DIESEL
First clean system to remove old glycol, see Cooling
System Cleaning.
(1) Disconnect upper radiator hose at thermostat
housing.
(2) Remove pressure cap from coolant expansion
tank.
(3) Fill cooling system through upper radiator hose
until coolant starts to leak out at the thermostat
housing. Reconnect hose and re-install clamp.
(4) Fill expansion tank to top of bottle. Run engine
at idle without pressure cap installed for 5 minutes.
Squeeze upper radiator hose several times.
(5) Shut off engine. Top off coolant and install
pressure cap.
(6) Inspect system for leaks.
REMOVAL AND INSTALLATION
WATER PUMP Ð 2.0L GASOLINE
REMOVAL
(1) Remove accessory drive belts and power steer-
ing pump.
(2) Drain cooling system.
Fig. 13 Coolant Pressure BottleÐ2.5L VM Diesel
Fig. 14 Pressure Cap and BottleÐVM Diesel
NS/GSCOOLING SYSTEM 7 - 7

(3) Remove power steering pump bracket bolts and
set pump and bracket assembly aside. Power steering
lines do not need to be disconnected.
(4) Remove timing belt.
(5) Remove inner timing belt cover.
(6) Remove water pump attaching screws to engine
(Fig. 15).
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 16). Use small dabs of Mopar Sil-
icone Rubber Adhesive Sealant around the water
pump body to secure O-ring in place during installa-
tion.
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring and cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 15 psi with pressure tester and check
water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install inner timing belt cover.
(5) Install timing belt.
(6) Fill cooling system. SeeFilling Cooling Sys-
tem.
(7) Install power steering pump and accessory
drive belts.
WATER PUMP Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system. Refer to Draining Cool-
ing System in this Group.
(2) Remove the right inner splash shield (Fig. 17).
(3) Loosen the water pump pulley attaching bolts
(Fig. 18) before the accessory drive belt is removed.
(4) Loosen water pump accessory drive belts (Fig.
19). Remove water pump pulley.(5) Remove water pump attaching bolts and
remove pump.
INSTALLATION
(1) Install a new water pump to housing O-ring
gasket. Install pump and tighten the attaching bolts
to 22.6 N´m (205 in. lbs.)
Fig. 15 Water Pump Ð 2.0L Gasoline
Fig. 16 Water Pump Body Ð 2.0L Gasoline
Fig. 17 Right Side Splash Shield
Fig. 18 Water Pump and Pulley Ð 2.5 L VM Diesel
7 - 8 COOLING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)

(2) Install water pump pulley.
(3) Install drive belt, Refer to Accessory Drive
Belts, this Group. Tighten water pump pulley attach-
ing bolts to 27.5 N´m (240 in. lbs.)
(4) Install right inner splash shield.
(5) Refill cooling system. Refer to Refilling Cooling
System in this Group.
ENGINE THERMOSTATÐ 2.0L GASOLINE
REMOVAL
(1) Drain cooling system to the thermostat level or
below.
(2) Remove coolant recovery system (CRS) hose
and thermostat/engine outlet connector bolts.
(3) Remove thermostat and seal, and clean sealing
surfaces.
INSTALLATION
(1) Place the new thermostat assembly into the
thermostat housing/outlet connector. Align air bleed
vent with notch in cylinder head.
(2) Install thermostat housing/outlet connector
onto cylinder head and tighten bolts to 12.5 N´m (110
in. lbs.). Connect the upper radiator hose.
(3) Refill cooling system (seeRefilling System).
THERMOSTAT Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
section.(2) Remove radiator hose at thermostat cover.
(3) Remove thermostat cover bolts (Fig. 20).
(4) Remove Thermostat.
INSTALLATION
(1) Remove old gasket material from thermostat
housing and cover.
(2) Install new thermostat gasket.
(3) Install thermostat and tighten cover bolts to
10.8 N´m (96 in. lbs.).
(4) Install radiator hose.
(5) Refill cooling system. Refer to Refilling Cooling
System in this section.
RADIATOR Ð 2.5L VM DIESEL
REMOVAL
(1) Disconnect battery.
(2) Remove power steering reservoir attaching
bolts, and reposition reservoir.
(3) Remove radiator closure panel crossmember
(Fig. 21).
(4) Remove air cleaner housing and intake hose.
(5) Unplug fan module 4 pin wiring connector.
(6) Drain cooling system. Refer to Draining cooling
system in this section for procedure.
(7) Remove upper and lower Radiator Hoses.
(8) Remove radiator attaching bolts.
(9) Loosen A/C receiver/dryer lower bolt.
(10) Remove Radiator.
(11) Remove fan module from radiator.
Fig. 19 Water Pump Drive BeltÐ 2.5 L VM Diesel
Fig. 20 Thermostat and Housing Ð 2.5L VM Diesel
NS/GSCOOLING SYSTEM 7 - 9
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install fan module on radiator.
(2) Install radiator.
(3) Tighten receiver/dryer lower bolt.
(4) Install radiator attaching bolts.
(5) Install lower and upper radiator hoses.
(6) Connect fan module.
(7) Install air cleaner housing and intake hose.
(8) Install radiator closure panel crossmember.
(9) Install power steering reservoir attaching bolts.
(10) Refill cooling system. Refer to Refilling cooling
system in this section for procedure.
(11) Connect battery.
WATER PUMP BELT Ð 2.5L VM DIESEL
REMOVAL
(1) Remove generator/power steering belt. Refer to
procedure in this section.
(2) Raise vehicle on hoist.
(3) Remove right side splash shield (Fig. 22).
(4) Loosen belt tensioner bracket bolts (Fig. 23).(5) Loosen adjuster lock nut.
(6) Loosen adjusting bolt, and remove belt.
INSTALLATION
(1) Install water pump belt.
(2) Turn adjusting bolt clockwise to tighten belt.
(3) Tighten lock nut.
(4) Tighten belt tensioner bracket bolts
(5) Lower vehicle.
(6) Install generator/power steering belt. Refer to
procedure in this section.
GENERATOR/POWER STEERING BELT Ð 2.5L VM
DIESEL
REMOVAL
(1) Loosen generator pivot bolt (Fig. 24).
(2) Loosen adjusting bracket bolt.
(3) Loosen adjusting nut.
(4) Remove generator/power steering belt.
INSTALLATION
(1) Install generator/power steering belt.
(2) Tighten adjusting nut.
(3) Tighten adjusting bracket bolt.
(4) Tighten generator pivot bolt.
CLEANING AND INSPECTION
WATER PUMP
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
Fig. 21 Radiator Closure Panel Crossmember
Fig. 22 Right Side Splash Shield
Fig. 23 Water Pump Belt Removal Ð 2.5L VM Diesel
7 - 10 COOLING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)