CHRYSLER VOYAGER 2002 Service Manual

(8) 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.
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 install upper screws (Fig.
12). Tighten fasteners to 5 N´m (45 in. lbs.).
(3) Install the radiator upper and lower hoses (Fig.
11).
(4) Connect the coolant bypass hose.
(5) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(6) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(7) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recom-
mended. Damage may occur to radiator or drain-
cock.
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(2) Open the draincock by turning it counterclock-
wise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 13) from the radiator
tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
(3) Tighten the draincock by turning clockwise
until it stops.
(4) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
Fig. 12 Radiator to A/C Condenser Mounting (left
mount shown, right similar)
1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR
2 - LOWER MOUNT
3 - A/C CONDENSER
Fig. 13 Draincock
1 - RADIATOR TANK
2 - DRAINCOCK
7a - 22 ENGINERG
RADIATOR (Continued)
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WATER PUMP
DESCRIPTION
The water pump on the 2.5L CRD diesel has a die
cast aluminum housing. It bolts to a aluminum hous-
ing which attaches to the engine block (Fig. 14).
OPERATION
The water pump is used to circulate coolant
through the cooling system. The coolant is pumped
through the engine block, cylinder head, heater core,
EGR cooler, cabin heater, and radiator.
REMOVAL
REMOVAL - WATER PUMP
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove timing belt inner and outer covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Remove water pump retaining bolts and pump
(Fig. 15).
REMOVAL - WATER PUMP HOUSING
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove both outer and inner timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Disconnect water pump housing to thermostat
housing bypass hose (Fig. 16).
(5) Remove the water pump housing retaining
nuts (Fig. 17).
(6) Remove water pump housing from engine block
(Fig. 17).
CLEANING
Clean gasket mating surfaces as necessary.
INSTALLATION
INSTALLATION - WATER PUMP
(1) Clean gasket mating surfaces as necessary.
(2) Place water pump and gasket in place. Install
water pump retaining bolts (Fig. 15). Torque bolts to
24.4N´m.
Fig. 14 WATER PUMP
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 15 WATER PUMP LOCATION
1 - CYLINDER HEAD
2 - ENGINE BLOCK
3 - OIL COOLER
4 - OIL FILTER HOUSING
5 - WATER PUMP
RGENGINE7a-23
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(3) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
INSTALLATION - WATER PUMP HOUSING
(1) Clean mating serfaces of water pump housing
and engine block as necessary.
(2) Place new o-ring in groove in water pump
housing (Fig. 18).
(3) Be sure lower radiator hose tube o-ring is in
place.
(4) Install water pump housing on lower radiator
hose tube and push on mounting studs (Fig. 17).
Torque retaining nuts to 24.4N´m.
(5) Connect water pump housing to thermostat
housing bypass hose (Fig. 16).
(6) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Connect negative battery cable.
Fig. 16 THERMOSTAT HOUSING LOCATION
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4 - WATER PUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - E G R VA LV E
Fig. 17 WATER PUMP ASSEMBLY
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 18 WATER PUMP HOUSING O-RING
1 - WATER PUMP
2 - WATER PUMP HOUSING O-RING
3 - WATER PUMP HOUSING
7a - 24 ENGINERG
WATER PUMP (Continued)
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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. 19).
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. 19) 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.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
PRESSURE CAP
Dip the pressure cap in water. Clean any deposits
off the vent valve or its seat and apply cap to end of
the Pressure Cap Test Adaptor that is included with
the Cooling System Tester 7700. Working the
plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at
least 97 kPa (14 psi), replace the pressure cap.
CAUTION: The Cooling System Tester Tool is very
sensitive to small air leaks that will not cause cool-
ing system problems. A pressure cap that does not
have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm
that cap is bad.
If the pressure cap tests properly while positioned
on Cooling System Tester (Fig. 20), but will not hold
pressure or vacuum when positioned on the filler
neck. Inspect the filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
Fig. 19 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 - PRESSURE BOTTLE
8 - FILLER NECK
Fig. 20 Testing Cooling System Pressure Cap
1 - PRESSURE CAP
2 - PRESSURE TESTER
RGENGINE7a-25
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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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RADIATOR FAN RELAY
DESCRIPTION
The low and high speed fan relays are mounted to
the upper radiator support above the charge air
cooler (Fig. 25).
OPERATION
The cooling system uses two fans. Both fans oper-
ate at two different speeds, low and high. Depending
on engine coolant temperature and A/C system high
side pressure, the fans operate at either low or high.
The ignition switch supplies voltage to the coil side of
the relay. When the ECM grounds the coil side of the
relay, the contacts close and the battery supplies
power to the fans.
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE
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.(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove upper radiator hose (Fig. 26).
REMOVAL - LOWER RADIATOR HOSE
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.
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove lower radiator hose (Fig. 26).
Fig. 25 RELAY LOCATIONS
1 - GLOW PLUG RELAY
2 - UPPER RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - RADIATOR FAN RELAYS
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID
Fig. 26 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-29
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REMOVAL - COOLANT BYPASS HOSE
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.
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove the coolant bypass hose (Fig. 26).
INSTALLATION
INSTALLATION - UPPER RADIATOR HOSE
(1) Install upper radiator hose (Fig. 26).(2) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
INSTALLATION - LOWER RADIATOR HOSE
(1) Install lower radiator hose (Fig. 26).
(2) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
INSTALLATION - COOLANT BYPASS HOSE
(1) Install cooling system bypass hose (Fig. 26).
(2) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
7a - 30 ENGINERG
COOLANT SYSTEM HOSES (Continued)
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AUDIO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - AUDIO..........1
ANTENNA BODY AND CABLE
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE..........................4
REMOVAL.............................4
INSTALLATION..........................5
ANTENNA MODULE - EXPORT
DESCRIPTION..........................6
OPERATION............................6
DIAGNOSIS AND TESTING - ANTENNA
MODULE - EXPORT....................6
REMOVAL.............................7
INSTALLATION..........................7
CD CHANGER
DESCRIPTION..........................7
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL.............................8INSTALLATION..........................8
QUARTER GLASS INTEGRAL ANTENNA -
EXPORT
DESCRIPTION..........................8
OPERATION............................8
DIAGNOSIS AND TESTING - QUARTER
GLASS INTEGRAL ANTENNA - EXPORT.....8
RADIO
DIAGNOSIS AND TESTING - RADIO..........9
REMOVAL.............................9
INSTALLATION.........................10
RADIO NOISE SUPPRESSION COMPONENTS
DESCRIPTION.........................10
OPERATION...........................10
REMOTE SWITCHES
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - REMOTE
SWITCHES..........................11
REMOVAL.............................12
INSTALLATION.........................12
SPEAKER
DIAGNOSIS AND TESTING - SPEAKER......12
REMOVAL.............................13
INSTALLATION.........................14
AUDIO
DESCRIPTION
There are four different system combinations avail-
able on this model. The available radio options are:
²AM/FM Cassette
²AM/FM Compact Disc with Compact Disc
changer controls
²AM/FM Cassette with single Compact Disc
Player and Compact Disc changer controls
²AM/FM Cassette with Compact Disc changer
controls
²AM/FM Cassette with Compact Disc player, rear
seat audio system and Compact Disc changer con-
trols.
The rear seat audio system allows passengers to
listen to a different music source, through head-
phones, other than what is playing through the vehi-
cles speaker system. A remote control is provided for
functions such as changing stations, tracks, disc and
modes while listening to rear seat audio. The radiomust be turned ON to use the rear seat audio sys-
tem.
All factory installed radio receivers are stereo Elec-
tronically Tuned Radios (ETR) and include and elec-
tronic digital clock function.
OPERATION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with this vehicle.
DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRB
IIIt, refer to the appropriate Diagnostic Service
Manual.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
RSAUDIO8A-1
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