CHRYSLER VOYAGER 2004 Service Manual

²Corrosion in the cooling system.
²Water pump seal may run dry, increasing the
risk of premature seal failure.
²Combustion gas leaks into the coolant can also
cause the above problems.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
Air can only be removed from the system by gather-
ing under the pressure cap. On the next heat up it will
be pushed past the pressure cap into the coolant recov-
ery bottle by thermal expansion of the coolant. It then
escapes to the atmosphere in the coolant recovery bottle
and is replaced with coolant on cool down.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
NOTE: Deaeration does not occur at engine idleÐ
higher engine speeds are required. Normal driving
will deaerate cooling system.
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE CAP, CYLINDER BLOCK
DRAIN PLUGS, OR THE DRAINCOCK WHEN THESYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1)Without removing radiator pressure cap
and with system not under pressure, open the
draincock. The draincock is located on the lower left
side of radiator (Fig. 5).
(2) After the coolant recovery/reserve container is
empty, then remove coolant pressure cap (Fig. 6).
(3) Remove the cylinder block drain plug(s).
Fig. 6 Cooling System Service Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
Fig. 5 Draincock Location
1 - LEFT SIDE FRAME RAIL
2 - DRAINCOCK
7 - 4 COOLINGRS
COOLING (Continued)

STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 6) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
For cooling system capacity, (Refer to LUBRICATION
& MAINTENANCE/FLUID CAPACITIES - SPECIFI-
CATIONS).
Fill coolant recovery/reserve container (Fig. 6) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 6). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the recovery/reserve container (Fig. 6). The
coolant level should be between the MIN and MAX
marks.
SPECIFICATIONS
ACCESSORY DRIVE BELT TENSION
ACCESSORY DRIVE BELT TENSION
2.4L ENGINE
Air Conditioning
Compressor/GeneratorDynamic Tensioner
Power
SteeringNew Belt534 - 756 N
(120 - 170 lbs.)
Used Belt*356 - 534 N
(80 - 120 lbs)
*Belt is considered used after 15 minutes of run-in
time
3.3/3.8L ENGINES
Air Conditioning Compressor
Dynamic Tensioner
Generator/Water Pump/
Power Steering
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Accessory Drive Belt Tensioner
Assembly (3.3/3.8L)ÐBolt28 Ð 250
Engine Coolant Temperature
Sensor
(2.4 & 3.3/3.8L) 7 Ð 60
Generator & A/C Compressor
Drive Belt Tensioner Assembly
(2.4L)ÐBolt54 40 Ð
Coolant Outlet Connector/
Thermostat Housing
(2.4 & 3.3/3.8L)ÐBolts 28 Ð 250
Water Pump
(2.4 & 3.3/3.8L)ÐBolts 12 Ð 105
Water Pump Inlet Tube
(2.4L)ÐBolts12 Ð 105
Water Pump Inlet Tube
(3.3/3.8L)ÐBolts28 Ð 250
Water Pump Pulley (3.3/3.8L)Ð
Bolts28 Ð 250
Radiator to A/C CondenserÐ
Screws5Ð45
Radiator FanÐScrews 5 Ð 45
Radiator Mounting (Upper
Bracket)ÐNuts12 Ð 105
RSCOOLING7-5
COOLING (Continued)

SPECIAL TOOLS
COOLING SYSTEM
Hose Clamp Pliers 6094
Hose Clamp Pliers 8495A
Cooling System Tester 7700
Coolant Refractometer 8286
DRB IIITwith PEP Module ± OT-CH6010A
Belt Tension Gauge Adapter 8371
Belt Tension Gauge 7198A
7 - 6 COOLINGRS
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT..........................7
DRIVE BELTS - 2.4L
STANDARD PROCEDURE - CHECKING
POWER STEERING BELT TENSION........8
REMOVAL.............................8
CLEANING.............................9
INSPECTION...........................9
INSTALLATION.........................10
ADJUSTMENTS........................10BELT TENSIONER - 2.4L
REMOVAL.............................10
INSTALLATION.........................10
DRIVE BELTS - 3.3/3.8L
REMOVAL.............................11
CLEANING............................11
INSPECTION..........................11
INSTALLATION.........................12
BELT TENSIONER - 3.3/3.8L
REMOVAL.............................12
INSTALLATION.........................12
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)
(b) Adjust power steering belt
tension (4 cyl. engine)
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley5. Replace pulley
RSACCESSORY DRIVE7-7

CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b) Adjust power steering belt
tension (4 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
DRIVE BELTS - 2.4L
STANDARD PROCEDURE - CHECKING POWER
STEERING BELT TENSION
WARNING: DO NOT CHECK BELT TENSION WITH
ENGINE RUNNING.
Accessory drive belt tension can be measured with
Special Tool 8371 ± Belt Tension Gauge Adapter, and
the DRBIIItusing the following procedures:
(1) Connect 8371 to the DRBIIItfollowing the
instructions provided with tool.
(2) Place end of microphone probe approximately
2.54 cm (1 in.) from belt at belt center span location
shown in (Fig. 1).
(3) Pluck the belt a minimum of 3 times. (Use your
finger or other suitable tool) The frequency of the
belt in hertz (Hz) will display on DRBIIItscreen.
(4) Adjust belt to obtain proper frequency (ten-
sion). Refer to ACCESSORY DRIVE BELT TENSION
CHART for belt tension specifications.
ACCESSORY DRIVE BELT TENSION CHART -
2.4L
Accessory Drive Belt Belt Tension
Air Conditioning
Compressor/GeneratorDynamic Tensioner
Power Steering PumpNew178 - 212
Hz
Used* 145 - 178
Hz
*A belt is considered used after 15 minutes of run-in
time.
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
Fig. 1 Power Steering Belt - Center Span Location
1 - POWER STEERING BELT CENTER SPAN LOCATION
7 - 8 ACCESSORY DRIVERS
DRIVE BELTS (Continued)

(3) Position a wrench on the belt tensioner lug
(Fig. 2).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 2).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (1)
and (2) (Fig. 3).
(2) From under the vehicle, loosen the pivot bolt
(3). Loosen adjusting bolt (4) until belt can be
removed.
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 4).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
Fig. 2 A/C & GENERATOR BELT TENSION RELEASE
1 - BELT TENSIONER
2 - WRENCH
Fig. 3 Power Steering Pump Belt
1 - REAR LOCKING NUT
2 - FRONT LOCKING NUT
3 - PIVOT BOLT
4 - ADJUSTING BOLT
Fig. 4 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RSACCESSORY DRIVE7-9
DRIVE BELTS - 2.4L (Continued)

INSTALLATION
GENERATOR AND AIR CONDITIONING BELT
(1) Install belt onto all pulleys except for the
crankshaft (Fig. 5).
(2) Rotate belt tensioner clockwise until belt can
be installed onto the crankshaft pulley (Fig. 2).
Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys (Fig. 5).
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
POWER STEERING PUMP
(1) Install belt over crankshaft and power steering
pump pulleys (Fig. 5).
(2) Apply an initial snug torque to pivot bolt (3)
and front locking nut (2) (Fig. 3).
(3) Tighten adjusting bolt (4) until proper belt ten-
sion is obtained (Fig. 3). For belt tension check pro-
cedure, (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - STANDARD PROCEDURE -
CHECKING POWER STEERING BELT TENSION).
(4) Tighten pivot bolt (3) and front locking nut (2)
to 54 N´m (40 ft. lbs.) (Fig. 3).
(5) Tighten rear locking nut (1) to 54 N´m (40 ft.
lbs.) (Fig. 3).
ADJUSTMENTS
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
7198. Because of space limitations in the engine com-
partment, the use of this gauge may be restricted.
Raise the vehicle on a hoist and the remove the
splash shield to gain access to the drive belts, if nec-
essary. Adjust belt tension for either aNeworUsed
belt. For specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE - SPECIFICATIONS).
BELT TENSIONER - 2.4L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the generator/A/C drive belt. (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove the belt tensioner (Fig. 6).
INSTALLATION
(1) Install belt tensioner and bolt (Fig. 6). Tighten
bolt to 54 N´m (40 ft. lbs.).
(2) Install generator/A/C compressor drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION)
(3) Install splash shield.
(4) Lower the vehicle.
Fig. 5 Accessory Drive Belts - 2.4L
1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING
Fig. 6 Belt Tensioner - 2.4L
1 - BELT TENSIONER
2 - GENERATOR BRACKET
3 - BOLT
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS - 2.4L (Continued)

DRIVE BELTS - 3.3/3.8L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 8).
(4) Release belt tension by rotating the tensioner
counterclockwise (Fig. 8).(5) Remove the drive belt (Fig. 10).
(6) Carefully return tensioner to its relaxed posi-
tion.CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 9).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
Fig. 7 Accessory Drive Belt Shield
1 - ATTACHING SCREW
2 - ATTACHING SCREWS
3 - SPLASH SHIELD
Fig. 8 DRIVE BELT TENSION RELEASE
1 - BELT TENSIONER LUG
2 - WRENCH
Fig. 9 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RSACCESSORY DRIVE7-11

INSTALLATION
(1) Route and position the drive belt onto all pul-
leys, except for the crankshaft (Fig. 10).
(2) Rotate belt tensioner counterclockwise until
belt can be installed onto the crankshaft pulley (Fig.
8). Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys.
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
BELT TENSIONER - 3.3/3.8L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
(4) Remove the belt tensioner (Fig. 11).
INSTALLATION
(1) Install the belt tensioner and bolt (Fig. 11).
Tighten bolt to 28 N´m (250 in. lbs.).
(2) Install the drive belt. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION)
(3) Install the drive belt shield.
(4) Lower the vehicle.
Fig. 10 ACCESSORY DRIVE BELT
1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY
Fig. 11 BELT TENSIONER - 3.3/3.8L
1 - BELT TENSIONER
2 - BOLT
7 - 12 ACCESSORY DRIVERS
DRIVE BELTS - 3.3/3.8L (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