CHRYSLER Voyager User Manual
GROUP TAB LOCATOR
Maintenance Schedules
0
Cooling 2.5L Turbo Diesel
7
Electronic Control Modules
8E
Engine Systems
8F
Ignition Control
8I
Engine
9
Exhaust System and Turbocharger
11
Fuel System
14
Emissions Control 2.5L Turbo Diesel
25
Service Manual Comment Forms (Rear of Manual)
RG MAINTENANCE SCHEDULES 0-1
MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page
MAINTENANCE SCHEDULES FOR ALL
MARKETS EXCEPT U.S., CANADA and
MEXICO
DESCRIPTION — DIESEL ENGINES .........1
MAINTENANCE SCHEDULES
FOR ALL MARKETS EXCEPT
U.S., CANADA and MEXICO
DESCRIPTION — DIESEL ENGINES
Maintenance Schedule Information not included in
this section, is located in the appropriate Owner’s
Manual.
There are two maintenance schedules that show
the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
• Extensive engine idling.
• Driving in dusty conditions.
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
NOTE: Most vehicles are operated under the conditions listed for Schedule ⴖBⴖ.
Second is Schedule “A”. It is for vehicles that are
not operated under any of the conditions listed under
Schedule ⬙B⬙.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.
At Each Stop for Fuel
• Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
improve the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
• Check the windshield washer solvent and add if
required.
Once a Month
• Check the tire pressure and look for unusual
wear or damage.
• Inspect the battery and clean and tighten the
terminals as required.
• Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and add as needed.
• Check all lights and all other electrical items for
correct operation.
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect the brake hoses.
• Inspect the CV joints and front suspension com-
ponents.
• Check the manual transmission fluid level.
• Check the coolant level, hoses, and clamps.
• Inspect engine accessory drive belts. Replace as
necessary.
• Inspect for the presence of water in the fuel filter/water separator unit.
• Rotate the tires at each oil change interval (20
000 km).
SCHEDULE “B”
Follow schedule “B” if you usually operate your
vehicle under one or more of the following conditions.
• Extensive engine idling.
• Driving in dusty conditions.
• More than 50% of your driving is at sustained
high speeds during hot weather, above 32° C (90° F).
• Trailer towing.
• Taxi, police, or delivery service (commercial ser-
vice).
0 - 2 MAINTENANCE SCHEDULES RG
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Change engine oil and engine oil filter. XXXXX
Inspect engine air filter element. Replace as
necessary.
Replace engine air filter element X X
Replace fuel filter/water separator unit. X X
Check front end alignment. X X
Change the manual transaxle fluid. X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings. XXXXX
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000 km
Change engine oil and engine oil filter. XXXXX
Inspect engine air filter element. Replace
as necessary.
Replace engine air filter element X X X
Replace fuel filter/water separator unit. X X X
Replace engine timing belt. X
Check front end alignment. X X
Change the manual transaxle fluid. X X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings. XXXXX
XXX
XX
Kilometers 110 000 km 120 000 km 130 000 km 140 000 km 150 000 km 160 000 km
Change engine oil and
engine oil filter.
Inspect engine air filter
element. Replace as
necessary.
Inspect accessory drive
belts and replace if
necessary.
Replace engine air filter
element
Replace fuel filter/water
separator unit.
Flush and replace engine
coolant.
Check front end alignment. X X X
Inspect the tie rod ends and
boot seals.
Inspect the brake linings. XXXXXX
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
XXXXXX
XXX
X
XXX
XXX
X
XX
RG MAINTENANCE SCHEDULES 0-3
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
SCHEDULE “A”
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000 km
Change engine oil and engine oil filter. XXXX X
Inspect engine air filter element. Replace
as necessary.
Replace engine air filter element X X
Replace fuel filter/water separator unit. XXXX X
Replace engine timing belt. X
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings. XXXX X
Kilometers 120 000 km 140 000 km 160 000 km 180 000 km
Change engine oil and engine oil filter. X X X X
Inspect engine air filter element. Replace as
necessary.
Inspect accessory drive belts and replace if
necessary.
Replace engine air filter element X X
Replace fuel filter/water separator unit. X X X X
Flush and replace engine coolant. X
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings. X X X X
XX X
XX
X
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
RG COOLING 2.5L TURBO DIESEL 7-1
COOLING 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM .........1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM .............................1
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TEST....................6
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK .................7
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION ....................7
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM
The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible, maintains
normal operating temperature and prevents overheating.
The cooling system also provides a means of heating the passenger compartment. The cooling system
is pressurized and uses a centrifugal water pump to
circulate coolant throughout the system. A separate
and remotely mounted, pressurized coolant tank
using a pressure/vent cap is used.
COOLING SYSTEM COMPONENTS
The cooling system consists of:
• Charge Air Cooler
• Electric Cooling Fans
• A aluminum-core radiator with plastic side
tanks
• A separate pressurized coolant tank
• A pressure/vent cap on the coolant tank
• Fan shroud
• Thermostat
• Coolant
• Low coolant warning lamp
• Coolant temperature gauge
• Water pump
• Hoses and hose clamps
CLEANING .............................7
INSPECTION ...........................7
SPECIFICATIONS
SPECIFICATIONS - TORQUE .............8
SPECIFICATIONS - COOLING SYSTEM
CAPACITY............................8
ACCESSORY DRIVE .......................9
ENGINE ...............................14
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as
the following may be the cause:
(1) PROLONGED IDLE, VERY HIGH AMBIENT
TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
OR STEEP GRADES.
• Idle with A/C off when temperature gauge is at
end of normal range.
(2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(3) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been performed on vehicle that may effect cooling system.
This may be:
• Engine adjustments (incorrect timing)
• Slipping engine accessory drive belt
• Brakes (possibly dragging)
• Changed parts (incorrect water pump)
• Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating complaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only.
7 - 2 COOLING 2.5L TURBO DIESEL RG
COOLING 2.5L TURBO DIESEL (Continued)
COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS LOW
TEMPERATURE GAUGE
READS HIGH. COOLANT
MAY OR MAY NOT BE
LOST OR LEAKING FROM
COOLING SYSTEM
1. Diesel engines, due to their
inherent efficiency are slower to
warm up than gasoline powered
engines, and will operate at lower
temperatures when the vehicle is
unloaded.
2. Is the temperature gauge
connected to the temperature gauge
coolant sensor on the engine?
3. Is the temperature gauge
operating OK?
4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.
5. Improper operation of internal
heater doors or heater controls.
1. Trailer is being towed, a steep hill
is being climbed, vehicle is operated
in slow moving traffic, or engine is
being idled with very high ambient
(outside) temperature and the air
conditioning is on. Higher altitudes
could aggravate these conditions.
2. Temperature gauge reading
incorrectly.
3. Coolant low in coolant tank and
radiator.
4. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered.
5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap
1. The low gauge reading may
be normal. Refer to thermostats
in the manual text for
information. See Thermostat
Diagnosis-Diesel Engine.
2. Check, the engine
temperature sensor connector
in the engine compartment.
3. Check gauge operation.
Repair as necessary.
4. Check coolant level in the
coolant tank. Inspect system for
leaks. Repair leaks as
necessary. Refer to the Coolant
section for WARNINGS and
precautions before removing
the pressure cap.
5. Inspect heater and repair as
necessary. Refer to Heating
and Air Conditioning for
procedures.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to
drive the vehicle without any of
the previous conditions.
Observe the temperature
gauge. The gauge should return
to the normal range. If the
gauge does not return to
normal range, determine the
cause for the overheating and
repair.
2. Check gauge. Refer to I/P
group.
3. Check for coolant leaks and
repair as necessary.
4. Tighten cap.
and cap seals. (b) Check
condition of coolant tank filler
neck. Make sure it does not
leak pressure.
RG COOLING 2.5L TURBO DIESEL 7-3
COOLING 2.5L TURBO DIESEL (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
6. Freeze point of antifreeze not
correct. Mixture may be too rich.
7. Coolant not flowing through
system.
8. Radiator or A/C condenser fins
are dirty or clogged.
9. Radiator core is corroded or
plugged.
10. Aftermarket A/C installed without
proper A/C condenser.
11. Dragging Brakes. 11. Check and correct as
12. Non-factory bug screen is being
used reducing air flow.
13. Thermostat partially or
completely shut. This is more
prevalent on high mileage vehicles.
14. Cylinder head gasket leaking. 14. Check cylinder head gasket
15. Heater core leaking. 15. Check heater core for
6. Check antifreeze. Adjust
antifreeze-to-water ratio as
required.
7. Check for coolant flow in
coolant tank with engine warm
and thermostat open. Coolant
should be observed flowing
through the tank. If flow is not
observed, determine reason for
lack of flow and repair as
necessary.
8. Clean debris from radiator or
A/C condenser
9. Have radiator re-cored or
replaced.
10. Install proper A/C
condenser.
necessary.
12. Only a factory screen
should be used.
13. Check thermostat and
replace if necessary.
for leaks.
leaks. Repair as necessary.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly. Fluctuation is also
influenced by loads, outside
temperature and extended idle time
with diesel engines.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running).
4. Gauge reading high after starting
a warm-up (hot) engine.
1. A normal condition. No
correction is necessary.
2. Check operation of gauge
and repair as necessary.
3. A normal condition. No
correction needed. Gauge
should return to normal range
after vehicle is driven.
4. A normal condition. No
correction needed. Gauge
should return to normal after a
few minutes of engine
operation.
7 - 4 COOLING 2.5L TURBO DIESEL RG
COOLING 2.5L TURBO DIESEL (Continued)
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 TANK
5. Coolant level low in the coolant
tank (air will build up in the cooling
system causing the thermostat to
open late).
6. Cylinder head gasket leaking
allowing exhaust gases to enter the
cooling system causing the
thermostat to open late.
7. Water pump impeller loose on
shaft.
8. Loose accessory drive belt (water
pump slipping).
9. Air leak on the suction side of the
water pump allowing air to build up
in the cooling system causing the
thermostat to open late.
1. Pressure relief valve in pressure/
vent cap is defective.
2. Head gasket leak or cracked
cylinder head.
5. Check and correct coolant
leaks.
6. (a) Check for cylinder head
gasket leaks with a
commercially available leak
tester. (b) Check for coolant in
engine oil. Inspect for white
steam emitting from exhaust
system. Repair as necessary.
7. Check water pump and
replace as necessary.
8. Check and correct as
necessary.
9. Locate leak and repair as
necessary.
1. Check condition of
pressure/vent cap and cap
seals.
2. Repair as necessary.
COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP
BLOWOFF. GAUGE IS
READING HIGH OR HOT
HOSE OR HOSES
COLLAPSE WHEN
ENGINE IS COOLING
NOISY FAN 1. Cooling fan blades loose. 1. Replace cooling fan
1. Coolant leaks in radiator, cooling
system hoses, water pump, or
engine.
1. Vacuum created in cooling system
on engine cool-down is not being
relieved through pressure/vent cap.
2. Cooling fan blades striking a
surrounding object.
3. Air obstructions at radiator or A/C
condenser.
1. Pressure test cooling system
and repair as necessary.
1. Cap relief valve stuck.
Replace if necessary.
assembly.
2. Locate point of fan blade
contact and repair as
necessary.
3. Remove obstructions or
clean debris from radiator or
A/C condenser.
RG COOLING 2.5L TURBO DIESEL 7-5
COOLING 2.5L TURBO DIESEL (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR
CONDITIONER
PERFORMANCE
(COOLING SYSTEM
SUSPECTED)
INADEQUATE HEATER
PERFORMANCE. MAY BE
ACCOMPANIED BY LOW
GAUGE READING
1. Radiator and/or A/C condenser is
restricted, obstructed or dirty
(insects, leaves, etc.)
2. Engine is overheating (heat may
be transferred from radiator to A/C
condenser. High Under hood
temperatures due to engine
overheating may also transfer heat
to A/C condenser).
3. The cooling system is 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.
1. Diesel engines, due to their
inherent efficiency are slower to
warm up than gasoline powered
engines, and will operate at lower
temperatures when the vehicle is
unloaded.
2. Coolant level low. 2. Pressure test cooling system.
3. Obstruction in heater hose fitting
at engine.
4. Heater hose kinked. 4. Locate kinked area. Repair
5. Water pump is not pumping water
to heater core. 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.
The accessory drive belt may also
be slipping causing poor water pump
operation.
1. Remove restriction or clean
debris from radiator or A/C
condenser.
2. Correct overheating
condition.
3. Check for missing or
damaged air seals. Repair as
necessary.
1. The lower gauge reading
may be normal.
Repair leaks as necessary.
3. Remove heater hoses and
check for obstructions. Repair
as necessary.
as necessary.
5. Refer to water pumps in this
group. Repair as necessary. If a
slipping belt is detected, refer to
Engine Accessory Drive Belts in
this group. Repair as
necessary.
7 - 6 COOLING 2.5L TURBO DIESEL RG
COOLING 2.5L TURBO DIESEL (Continued)
CONDITION POSSIBLE CAUSES CORRECTION
HEAT ODOR 1. Various heat shields are used at
certain drive line components. One
or more of these shields may be
missing.
2. Is temperature gauge reading
above the normal range?
3. Is the Cooling fan operating
correctly?
4. Has undercoating been applied to
any unnecessary components?
STEAM IS COMING FROM
FRONT OF VEHICLE
NEAR GRILL AREA WHEN
WEATHER IS WET,
ENGINE IS WARMED UP
AND RUNNING, AND
VEHICLE IS STATIONARY.
TEMPERATURE GAUGE
IS IN NORMAL RANGE
COOLANT ODOR 1. Coolant color is not necessarily an
1. During wet weather, moisture
(snow, ice, or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water 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.
indication of adequate corrosion or
temperature protection. Do not rely
on coolant color for determining
condition of coolant.
1. Locate missing shields.
Repair or replace as necessary.
2. Refer to the previous
Temperature Gauge Reads
High in these Diagnostic
Charts. Repair as necessary.
3. Refer to Cooling System Fan
in this group for diagnosis.
Repair as necessary.
4. Clean undercoating as
necessary.
1. Occasional steam emitting
from this area is normal. No
repair is necessary.
1. Refer to Coolant in this group
for antifreeze tests. Adjust
antifreeze-to-water ratio as
necessary.
COOLANT LEVEL
CHANGES IN COOLANT
TANK. TEMPERATURE
GAUGEISINNORMAL
RANGE
1. Level changes are to be expected
as coolant volume fluctuates with
engine temperature. If the level in
the tank was between the HOT and
COLD marks at normal engine
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAK TEST
WARNING: THE WARNING WORDS “DO NOT OPEN
HOT” 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. This a normal condition. No
repair necessary.
With engine not running, remove pressure/vent cap
from the coolant recovery pressure container and
wipe the filler neck sealing seat clean. The coolant
recovery pressure container should be full.
Attach the Cooling System Tester 7700 or equivalent to the radiator, as shown in (Fig. 1) 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.
RG COOLING 2.5L TURBO DIESEL 7-7
COOLING 2.5L TURBO DIESEL (Continued)
DIAGNOSIS AND TESTING - COOLING SYSTEM
FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use the following procedures:
(1) If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper
radiator hose. If it is hot, coolant is circulating.
WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM COOLANT CAN OCCUR.
(2) Remove pressure/vent cap when engine is cold,
idle engine until thermostat opens, you should
observe coolant flow while looking down in the coolant recovery pressure container. Once flow is
detected install the pressure/vent cap.
DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
Fig. 1 PRESSURE TESTING COOLING SYSTEM
1 - COOLING SYSTEM PRESSURE TESTER
2 - COOLANT RECOVERY PRESSURE CONTAINER
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 system
tester. 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 gasket, cracked engine block, or cracked cylinder head.
There may be internal leaks that can be determined 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.
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 aeration. Aeration will draw air into the water pump
resulting in the following:
• High reading shown on the temperature gauge.
• Loss of coolant flow through the heater core.
• Corrosion in the cooling system.
• Water pump seal may run dry, increasing the
risk of premature seal failure.
• Combustion gas leaks into the coolant can also
cause aeration.
CLEANING
Drain cooling system and refill with clean water.
Refer to procedures in this section. Run engine with
pressure/vent 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.
INSPECTION
After performing a cleaning/flush procedure,
inspect all hoses, clamps and connections for deterioration and leaks. Inspect radiator and heater core for
leaks.
7 - 8 COOLING 2.5L TURBO DIESEL RG
COOLING 2.5L TURBO DIESEL (Continued)
SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Water Pump Housing Nuts 24.4 18 215
Thermostat Housing Bolts 27.5 21 —
Accessory Drive Belt
Tensioner Bolt
Accessory Drive Belt Idler
Bolt
47.1 35 —
53 39 —
SPECIFICATIONS - COOLING SYSTEM
CAPACITY
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Cooling System With
Auxiliary Heater
Cooling System With Out
Auxiliary Heater
16.6 Liters (17.5 qts.)
13.8 Liters (14.6 qts.)
RG ACCESSORY DRIVE 7-9
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE
SPECIFICATIONS - ACCESSORY BELT
TENSION .............................9
BELT TENSIONER
REMOVAL .............................9
INSTALLATION ..........................9
IDLER PULLEY
REMOVAL .............................10
INSTALLATION .........................10
DRIVE BELTS
DESCRIPTION
DESCRIPTION - ACCESSORY DRIVE BELT . 10
ACCESSORY DRIVE
SPECIFICATIONS - ACCESSORY BELT TENSION
ACCESSORY DRIVE
BELT
2.5L DIESEL ENGINE
A/C Compressor/
Generator
Power Steering Belt 300 N (67 lbs.)
GAUGE
Dynamic Tensioner
DESCRIPTION - POWER STEERING BELT . . 10
OPERATION
OPERATION-ACCESSORY DRIVE BELT ....10
OPERATION-POWER STEERING BELT .....11
DIAGNOSIS AND TESTING - ACCESSORY
DRIVEBELT .........................11
REMOVAL
REMOVAL-ACCESSORY DRIVE BELT ......11
REMOVAL ...........................11
INSTALLATION
INSTALLATION-ACCESSORY DRIVE BELT . . 13
INSTALLATION-POWER STEERING BELT . . . 13
BELT TENSIONER
REMOVAL
WARNING:: BECAUSE OF HIGH SPRING TENSION,
DO NOT ATTEMPT TO DISASSEMBLE THE AUTOMATIC BELT TENSIONER. THE TENSIONER IS SERVICED AS AN ASSEMBLY.
(1) Remove the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(2) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(3) Remove the belt tensioner retaining bolt and
remove tensioner (Fig. 1).
Fig. 1 BELT TENSIONER AND IDLER PULLEY
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
INSTALLATION
(1) Install belt tensioner and retaining bolt (Fig.
1). Torque bolt to 47 N·m (35ft. lbs.).
(2) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
7 - 10 ACCESSORY DRIVE RG
BELT TENSIONER (Continued)
(3) Install the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
IDLER PULLEY
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
CAUTION: IDLER PULLEY RETAINING BOLT HAS
LEFT HAND THREAD
(2) Remove the idler pulley (Fig. 2).
DRIVE BELTS
DESCRIPTION
DESCRIPTION - ACCESSORY DRIVE BELT
The accessory drive belt is a serpentine type belt
(Fig. 3). Satisfactory performance of these belts
depends on belt condition and proper belt tension.
Fig. 2 BELT TENSIONER AND IDLER PULLEY
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
INSTALLATION
(1) Install the idler pulley (Fig. 2). Torque retain-
ing bolt to 22 N·m (16 ft. lbs.).
(2) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(3) Install the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
Fig. 3 ACCESSORY DRIVE BELT ROUTING
1 - GENERATOR
2 - IDLER PULLEY
3 - A/C COMPRESSOR CLUTCH
4 - POWER STEERING PUMP PULLEY
5 - POWER STEERING BELT
6 - CRANKSHAFT DAMPER/PULLEY
7 - BELT TENSIONER
8 - ACCESSORY DRIVE BELT
DESCRIPTION - POWER STEERING BELT
The power steering belt is a serpentine type belt
(Fig. 3). Satisfactory performance of this belt depends
on condition of the belt.
OPERATION
OPERATION-ACCESSORY DRIVE BELT
The accessory drive belts form the link between
the engine crankshaft and the engine driven accessories.
RG ACCESSORY DRIVE 7-11
DRIVE BELTS (Continued)
OPERATION-POWER STEERING BELT
The power steering belt forms a link between the
engine crankshaft and the power steering pump.
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE
BELT SQUEAL WHEN
ACCELERATING ENGINE
BELT SQUEAK AT IDLE 1. Belts too loose 1. Replace belt
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF
1. Belt too loose 1. Replace belt (auto-tensioned
belts)
2. Faulty belt tensioner 2. Replace tensioner as necessary
3. Belt excessively glazed or worn 3. Replace belt
1. Belts too loose 1. Check and replace belt tensioner
if necessary
2. Belt glazed 2. Replace belt
2. Dirt or paint imbedded in belt or
pulley
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley
1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. Replace belt
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley
2. Replace belt, clean pulley
5. Replace pulley
4. Replace pulley
REMOVAL
REMOVAL-ACCESSORY DRIVE BELT
(1) Remove the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).
(2) Relieve tension on belt tensioner using a suitable wrench (Fig. 4) and lock tensioner with a drift
punch (Fig. 5).
(3) Remove the accessory drive belt.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right front fender inner splash shield.
(3) Install power steering belt remover tool on
crankshaft damper (Fig. 6).
(4) Rotate engine clockwise to remove belt (Fig. 7).
7 - 12 ACCESSORY DRIVE RG
DRIVE BELTS (Continued)
Fig. 4 ACCESSORY DRIVE BELT REMOVAL
1 - BELT TENSIONER
2 - ACCESSORY DRIVE BELT
3 - IDLER PULLEY
4 - A/C COMPRESSOR CLUTCH
5 - CRANKSHAFT DAMPER/PULLEY
6 - WRENCH
Fig. 6 POWER STEERING BELT REMOVAL TOOL
1 - VIBRATION DAMPER
2 - POWER STEERING PULLEY
3 - POWER STEERING BELT
4 - POWER STEERING BELT REMOVER
Fig. 5 LOCKING/LOCKING BELT TENSIONER
Fig. 7 POWER STEERING BELT REMOVAL
1 - VIBRATION DAMPER
2 - POWER STEERING BELT
3 - POPWER STEERING BELT REMOVER
RG ACCESSORY DRIVE 7-13
DRIVE BELTS (Continued)
INSTALLATION
INSTALLATION-ACCESSORY DRIVE BELT
(1) Install the accessory drive belt in proper popsition (Fig. 8).
Fig. 8 ACCESSORY DRIVE BELT ROUTING
1 - GENERATOR
2 - IDLER PULLEY
3 - A/C COMPRESSOR CLUTCH
4 - POWER STEERING PUMP PULLEY
5 - POWER STEERING BELT
6 - CRANKSHAFT DAMPER/PULLEY
7 - BELT TENSIONER
8 - ACCESSORY DRIVE BELT
(2) Unlock belt tensioner by removing punch and
apply tension to accessory drive belt (Fig. 9).
(3) Install the power steering belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
INSTALLATION-POWER STEERING BELT
(1) Install power steering belt installation tool
(Fig. 10).
(2) Install power steering belt on crankshaft and
rotate crankshaft clockwise until belt is fully
installed on crankshaft (Fig. 10).
(3) Remove installation tool from crankshaft.
(4) Install right front fender inner splash shield.
(5) Lower vehicle from hoist.
Fig. 9 LOCKING/UNLOCKING BELT TENSIONER
Fig. 10 POWER STEERING BELT INSTALLATION
1 - POWER STEERING BELT
2 - HOLDING HOOK
3 - POWER STEERING PUMP PULLEY
4 - VIBRATION DAMPER
5 - POWER STEERING BELT INSTALLATION TOOL
7 - 14 ENGINE RG
ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION .........................15
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING .............15
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
SERVICE............................16
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................16
STANDARD PROCEDURE - COOLANT
LEVEL CHECK........................16
STANDARD PROCEDURE - COOLING
SYSTEM FILLING .....................16
STANDARD PROCEDURE - COOLING
SYSTEM DRAINING....................17
COOLANT RECOVERY PRESS CONTAINER
DESCRIPTION .........................17
OPERATION ...........................17
REMOVAL .............................18
INSTALLATION .........................18
ENGINE COOLANT TEMP SENSOR
DESCRIPTION .........................18
OPERATION ...........................18
REMOVAL .............................19
INSTALLATION .........................19
ENGINE COOLANT THERMOSTAT
DESCRIPTION .........................20
OPERATION ...........................20
REMOVAL .............................20
INSTALLATION .........................20
RADIATOR
DESCRIPTION .........................21
OPERATION ...........................21
REMOVAL .............................21
INSTALLATION .........................21
RADIATOR DRAINCOCK
REMOVAL .............................22
INSTALLATION .........................22
WATER PUMP
DESCRIPTION .........................22
OPERATION ...........................22
REMOVAL
REMOVAL-WATERPUMP ..............22
REMOVAL-WATERPUMPHOUSING ......22
CLEANING ............................23
INSTALLATION
INSTALLATION-WATERPUMP ..........23
INSTALLATION - WATER PUMP HOUSING . . 23
RADIATOR PRESSURE CAP
DESCRIPTION .........................23
OPERATION ...........................24
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP...............25
DIAGNOSIS AND TESTING - PRESSURE
RELIEFTEST ........................25
CLEANING ............................26
INSPECTION ..........................26
RADIATOR FAN
DESCRIPTION .........................26
OPERATION ...........................26
DIAGNOSIS AND TESTING - RADIATOR FAN
MOTOR .............................27
REMOVAL .............................27
INSTALLATION .........................27
HOSE CLAMPS
DESCRIPTION - HOSE CLAMPS ...........28
OPERATION - HOSE CLAMPS .............28
RADIATOR FAN RELAY
DESCRIPTION .........................28
OPERATION ...........................28
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE .....29
REMOVAL-LOWERRADIATORHOSE .....29
REMOVAL-COOLANTBYPASSHOSE .....29
INSTALLATION
INSTALLATION - UPPER RADIATOR HOSE . . 29
INSTALLATION - LOWER RADIATOR HOSE . 29
INSTALLATION - COOLANT BYPASS HOSE . 29
RG ENGINE 7-15
COOLANT
DESCRIPTION
Coolant flows through the engine water jackets
and cylinder heads absorbing heat produced by the
engine during operation. The coolant carries heat to
the radiator and heater core. Here it is transferred to
ambient air passing through the radiator and heater
core fins.
The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of
44 percent, year-round in all climates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol—Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300 deg. F). This temperature is hot
enough to melt plastic and soften solder. The
increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes
at -22 deg. C (-8 deg. F ).
Propylene-glycol Formulations—Should Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications. It’s overall effec-
tive temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol
and water is -32 deg. C (-26 deg. F). 5 deg. C higher
than ethylene-glycol’s freeze point. The boiling point
(protection against summer boil-over) of propyleneglycol is 125 deg. C (257 deg.F)at96.5 kPa (14 psi),
compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or
freeze-up in Chrysler vehicles, which are designed for
ethylene-glycol. Propylene glycol also has poorer heat
transfer characteristics than ethylene glycol. This
can increase cylinder head temperatures under certain conditions.
Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be
Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
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 -37°C
(-34°F) to -59°C (-50°F). The use of a hydrometer or a
refractometer can be used to test coolant concentration.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mixture. 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 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 glycols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended.
CAUTION: Do not mix types of coolant—corrosion
protection will be severely reduced.
7 - 16 ENGINE RG
COOLANT (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAINTENANCE SCHEDULES - DESCRIPTION).
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The pressure/vent cap should not be removed
from the coolant recovery pressure container
when the engine is hot. When additional coolant is
needed to maintain this level, it should be added to
the coolant recovery pressure container (Fig. 1). Use
only 50/50 mix of ethylene glycol type antifreeze and
distilled water. For the recommeded antifreeze/coolant type (Refer to LUBRICATION & 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 pressure/vent cap for routine
coolant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the pressure/vent cap. With the engine
cold and not running, simply observe the level of
the coolant in the coolant recovery pressure container
(Fig. 2). The coolant level should be between the MIN
and MAX marks.
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
(1) Remove pressure vent cap from coolant recovery pressure container.
(2) Loosen air bleed screw on the thermostat housing.
(3) Slowly fill the cooling through the coolant
recovery pressure container until a steady stream of
coolant comes out of the air bleed.
(4) Tighten the air bleed screw.
(5) Continue filling coolant recovery pressure container until level reaches the full line.
Fig. 1 UNDERHOOD FLUID FILL LOCATIONS
1 - COOLANT PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - INTELLIGENT POWER MODULE
4 - BATTERY
5 - COOLANT RECOVERY PRESSURE CONTAINER
6 - OIL DIPSTICK
7 - WINDSHIELD SOLVENT RESEVOIR
8-AIRFILTERHOUSING
9 - ENGINE OIL FILL CAP
RG ENGINE 7-17
COOLANT (Continued)
(1) Without removing pressure/vent cap and
with system not under pressure, open the drain-
cock. The draincock is located on the lower right side
of radiator (Fig. 3).
(2) After the coolant recovery pressure container is
empty, then remove coolant pressure/vent cap.
Fig. 2 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
(6) Without installing the pressure/vent cap, start
and run engine at idle for a couple minutes.
(7) Recheck coolant level and fill as necessary.
(8) Install pressure/vent cap and drive vehicle for
approx. 10 km to reach normal operating temperatures.
(9) Allow vehicle to cool. Check and fill coolant as
needed.
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Fig. 3 DRAINCOCK LOCATION
1 - RADIATOR
2 - DRAINCOCK
3-LOWERRADIATORSUPPORT
4 - ELECTRIC COOLING FAN
COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
The coolant recovery pressure container is
mounted in the engine compartment next to the battery. The coolant recovery pressure container is made
of plastic (Fig. 4).
OPERATION
The coolant recovery pressure container works
with the pressure/vent cap to use thermal expansion
and contraction 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 pressure/vent cap. It also provides some reserve coolant
to cover deaeration, evaporation, or boiling losses.
7 - 18 ENGINE RG
COOLANT RECOVERY PRESS CONTAINER (Continued)
Fig. 4 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
REMOVAL
(1) Drain cooling system below level of coolant
recovery pressure bottle. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)
(2) Disconnect coolant bypass and overflow hoses
from coolant recovery pressure container (Fig. 6).
(3) Unclip the coolant recovery pressure container
retaining clip (Fig. 5).
(4) Raise coolant recovery pressure container from
mounting bracket and disconnect coolant hose from
bottom of container (Fig. 6).
(5) Remove coolant recovery pressure bottle.
INSTALLATION
(1) Connect coolant hose at bottom of coolant
recovery pressure container (Fig. 6) and install in
mounting bracket.
(2) Connect coolant recovery pressure container
retaining clip (Fig. 5).
(3) Connect coolant bypass and overflow hoses to
coolant recovery pressure container.
Fig. 5 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
(4) Refill cooling system. (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE)
ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 7).
New sensors have sealant applied to the threads.
OPERATION
The coolant temperature (ECT) sensor is a negative temperature coefficient (NTC) thermistor (resistance varies inversley with temperature). This means
at cold tempertures its resistance is high so the voltage signal will be high. As coolant temperture
increases, resistance decreases and the signal voltage
will be low. This allows the sensor to provide an analog voltage signal to the ECM.
RG ENGINE 7-19
ENGINE COOLANT TEMP SENSOR (Continued)
REMOVAL
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1) Drain the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)
(2) Disconnect coolant temperature sensor electrical connector (Fig. 8).
(3) Remove coolant temperature sensor from cylinder head (Fig. 8).
Fig. 6 COOLANT RECOVERY PRESSURE
CONTAINER
1 - COOLANT RECOVERY PRESSURE CONTAINER
2 - COOLANT BYPASS HOSE
3 - OUTLET HOSE
4 - PRESSURE/VENT CAP
Fig. 7 COOLANT TEMPERATURE SENSOR
LOCATION
1 - EGR SOLENOID
2 - UPPER RADIATOR HOSE
3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
Fig. 8 COOLANT TEMPERATURE SENSOR
LOCATION
1 - EGR SOLENOID
2 - UPPER RADIATOR HOSE
3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
INSTALLATION
(1) Install coolant temperature sensor in cylinder
head (Fig. 8).
(2) Connect coolant temperature sensor electrical
connector (Fig. 8).
(3) Refill the cooling system. (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE)
(4) Connect the negative battery cable.
7 - 20 ENGINE RG
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator (Fig. 9).
REMOVAL
NOTE: The thermostat is not serviced separately.
The thermostat and housing must be replaced as
an assembly.
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove front wiper unit to gain access to thermostat housing(Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
(4) Disconnect upper radiator hose adapter tube,
water pump hose, and EGR hose at thermostat housing.
(5) Remove both thermostat housing attaching
bolts and housing (Fig. 10).
Fig. 9 THERMOSTAT HOUSING
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4-WATERPUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - EGR VALVE
OPERATION
The thermostat starts to open at 88°C (190°F).
Above this temperature, coolant is allowed to flow to
the radiator. This provides quicker engine warmup
and overall temperature control.
The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing.
Operating without a thermostat causes other problems. These are: longer engine warmup time, unreliable warmup performance, increased exhaust
emissions and crankcase condensation. This condensation can result in sludge formation.
Fig. 10 THERMOSTAT HOUSING ASSEMBLY
1 - THERMOSTAT HOUSING GASKET
2 - THERMOSTAT HOUSING
3 - RETAINING BOLTS
4 - CYLINDER HEAD
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
INSTALLATION
(1) Install thermostat housing, gasket, and retain-
ing bolts (Fig. 10). Torque bolts to 27.5N·m.
(2) Connect upper radiator hose adapter tube,
water pump hose, and EGR cooler hose to thermostat
housing.
RG ENGINE 7-21
ENGINE COOLANT THERMOSTAT (Continued)
(3) Install front wiper unit (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
RADIATOR
DESCRIPTION
The radiator is a cross-flow type (horizontal tubes)
with design features that provide greater strength
along with sufficient heat transfer capabilities to
keep the engine satisfactorily cooled. The radiator
has plastic side tanks and aluminum cooling tubes.
OPERATION
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
Fig. 11 UPPER AND LOWER RADIATOR HOSES
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 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Remove the radiator fans. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL)
(5) Disconnect coolant bypass hose (Fig. 11).
(6) Disconnect upper and lower hoses from the
radiator (Fig. 11).
(7) Remove the A/C condenser side brackets to
radiator attaching screws (Fig. 12). Separate the condenser from the radiator by lifting upward to disengage from lower mounts (Fig. 12). Allow the
condenser to rest in front of radiator.
(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.
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5-LOWERRADIATORHOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
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.
7 - 22 ENGINE RG
RADIATOR (Continued)
Fig. 13 Draincock
1 - RADIATOR TANK
2 - DRAINCOCK
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
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock.
NOTE: It is not necessary to remove draincock during a routine coolant drain.
(1) Drain the cooling system (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Open the draincock by turning it counterclockwise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 13) from the radiator
tank.
(4) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
WATER PUMP
DESCRIPTION
The water pump on the 2.5L CRD diesel has a die
cast aluminum housing. It bolts to a aluminum housing 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).
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.
REMOVAL - WATER PUMP HOUSING
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
RG ENGINE 7-23
WATER PUMP (Continued)
Fig. 14 WATER PUMP
1 - WATER PUMP HOUSING STUDS
2-WATERPUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
(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.
(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.
Fig. 15 WATER PUMP LOCATION
1 - CYLINDER HEAD
2 - ENGINE BLOCK
3 - OIL COOLER
4 - OIL FILTER HOUSING
5-WATERPUMP
INSTALLATION - WATER PUMP HOUSING
(1) Clean mating surfaces 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.
RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system pressure cap is located on the
coolant recovery pressure container. The cap construction includes; stainless steel swivel top, rubber
seals, and retainer, main spring, and a spring loaded
valve (Fig. 19).
7 - 24 ENGINE RG
RADIATOR PRESSURE CAP (Continued)
Fig. 16 THERMOSTAT HOUSING LOCATION
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4-WATERPUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - EGR VALVE
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 radiator 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 coolant 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. 17 WATER PUMP ASSEMBLY
1 - WATER PUMP HOUSING STUDS
2-WATERPUMP
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-WATERPUMP
2 - WATER PUMP HOUSING O-RING
3-WATERPUMPHOUSING
RG ENGINE 7-25
RADIATOR PRESSURE CAP (Continued)
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-FILLERNECK
Fig. 20 Testing Cooling System Pressure Cap
1 - PRESSURE CAP
2 - PRESSURE TESTER
DIAGNOSIS AND TESTING - PRESSURE
RELIEF TEST
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.
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 gasket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at 55 kPa (8 psi) minimum.
CAUTION: The Cooling System Tester Tool is very
sensitive to small air leaks that will not cause cooling 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. 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-FILLERNECK
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