Engine Cooling System: Removal & Installation Chrysler Voyager IV

INSTALLATION

1. Connect the recovery hose to container see scheme 7
2. Position the recovery container on the frame rail see scheme 7
3. Install the upper attaching screw and tighten to 7 N-m (60 in. lbs.) see scheme 7
4. Raise the vehicle on hoist.
5. Install the lower attaching screws and tighten to 8.5 N-m (75 in. lbs.) see scheme 7
6. Lower the vehicle.
7. Add coolant to container as necessary. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

REMOVAL

1. Drain coolant from radiator and cylinder block. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
2. Disconnect the power cord plug from heater.
3. Loosen screw in center of heater. Remove the heater assembly.

1. Clean block core hole and heater seat.
2. Insert heater assembly with element loop positioned upward.
3. With heater seated, tighten center screw securely to assure a positive seal.
4. Install power cord plug to heater.
5. Fill cooling system with coolant to the proper level. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

Scheme 30

1. Drain the cooling system below thermostat level. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
2. Disconnect coolant temperature sensor electrical connector.
3. Remove coolant temperature sensor (Scheme 30)

1. Install coolant temperature sensor (Scheme 30) Tighten sensor to 7 N-m (60 in. lbs.).
2. Connect electrical connector to sensor.
3. Fill cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

Scheme 31

Scheme 32

Scheme 33

1. Drain cooling system below engine coolant temperature sensor level. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
2. Remove power steering reservoir and relocate (Scheme 31) Do not disconnect hoses.
3. Remove ignition coil and bracket (Scheme 32)
4. Disconnect coolant sensor electrical connector (Scheme 33)
5. Remove coolant sensor (Scheme 33)

1. Install engine coolant temperature sensor (Scheme 33) Tighten sensor to 7 N-m (60 in. lbs.).
2. Connect electrical connector to sensor (Scheme 33)
3. Install ignition coil bracket (Scheme 32)
4. Install ignition coil (Scheme 32)
5. Install power steering reservoir (Scheme 31)
6. Fill cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

1. Place a new gasket (dipped in clean water) on the coolant outlet connector surface. Position thermostat with air bleed at the 12 o'clock position in thermostat housing see scheme 13
2. Position the coolant outlet connector and gasket over the thermostat, making sure thermostat is seated in the thermostat housing.
3. Position outlet connector to thermostat housing and install bolts see scheme 13 Tighten bolts to 28 N-m (250 in. lbs.).
4. Install the radiator upper hose to coolant outlet housing see scheme 12
5. Refill the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

Scheme 34

Scheme 35

1. Drain cooling system down below the thermostat level. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
2. Remove radiator upper hose from coolant outlet connector (Scheme 34)
3. Remove coolant outlet connector bolts and connector (Scheme 35)
4. Remove thermostat from outlet connector.
5. Discard gasket and clean both gasket sealing surfaces.

Scheme 36

Scheme 37

1. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place (Scheme 36) It is not necessary to restake the replacement thermostat into the connector.
2. Position thermostat to coolant outlet connector. Align the two locating notches on thermostat to the connector (Scheme 37) This position will ensure proper location of the thermostat air bleed.
3. Position a new gasket over the thermostat and connector making sure thermostat is in proper position and in the recess provided.
4. Install thermostat and connector assembly to the intake manifold (Scheme 35) Tighten bolts to 28 N.m (250 in. lbs.).
5. Install the radiator upper hose to coolant outlet connector (Scheme 34)
6. Refill the cooling system to the proper level. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

Scheme 38

Scheme 39

Scheme 40

1. Disconnect negative cable from battery.
2. Remove radiator upper crossmember support.
3. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
4. Remove the radiator fans. (Refer to «REMOVAL»(ref-338220-S27575324862009081800000) ).
5. Disconnect coolant reserve/recovery hose.
6. Remove vapor purge solenoid from mounting bracket.
7. Disconnect upper and lower hoses from the radiator (Scheme 38) or (Scheme 39)
8. Remove the A/C condenser side brackets to radiator attaching screws (Scheme 40) Separate the condenser from the radiator by lifting upward to disengage from lower mounts (Scheme 40) Allow the condenser to rest in front of radiator.
9. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

1. Be sure the air seal is in position before radiator is installed. Slide radiator down into position. 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 (Scheme 40) Tighten fasteners to 5 N.m (45 in. lbs.).
3. Install the radiator upper and lower hoses (Scheme 38) or (Scheme 39)
4. Connect the coolant reserve/recovery hose.
5. Connect the vapor purge solenoid to the mounting bracket.
6. Install the radiator fans. (Refer to «INSTALLATION»(ref-338220-S02643625932009081800000) ).
7. Install the radiator upper crossmember support.
8. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
9. Connect negative cable to battery.

Note. It is not necessary to remove draincock during a routine coolant drain.

Scheme 41

1. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
2. Open the draincock by turning it counterclockwise until it stops.
3. Turn the draincock back (clockwise) 1/8 turn.
4. Pull the draincock (Scheme 41) from the radiator tank.

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 «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

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 assembly (Scheme 42)

Scheme 42

1. Remove the radiator upper crossmember.
2. Disconnect the radiator fan electrical connectors.
3. Remove radiator fan(s) retaining screw (Scheme 42)
4. Remove the radiator fan(s) by lifting upward to release from mounts.

1. Install the radiator fan(s) into mounts and attaching clips on the radiator.
2. Install radiator fan(s) attaching screws (Scheme 42) Tighten to 5 N.m (45 in. lbs.).
3. Connect the radiator fan(s) electrical connectors.
4. Install the radiator upper support crossmember.
5. Install the upper radiator mounts to the crossmember bolts, if removed. Tighten to 8 N.m (70 in. lbs.).
6. Install the radiator upper hose to the support clip (2.4L engine).

1. Position relay and install a new rivet see scheme 29
2. Connect electrical connector to relay.
3. Install closure panel and attaching screws.
4. Connect negative cable to battery.

1. Install new O-ring gasket in water pump body O-ring locating groove see scheme 33
2. Assemble pump body to block and tighten screws to 12 N.m (105 in. lbs.) see scheme 32 Pressurize cooling system to 103.4 kPa (15 psi) with pressure tester and check water pump shaft seal and O-ring for leaks.
3. Rotate pump by hand to check for freedom of movement.
4. Install the timing belt rear cover (Refer to «TIMING BELT COVER(S)»(ref-189920-S05399853052005091600000) ).
5. Install camshaft sprockets and torque bolts to 101 N-m (75 ft. lbs.) while holding camshaft sprocket with Special tool C-4687 and adaptor C-4687-1.
6. Install timing belt idler pulley and torque mounting bolt to 61 N-m (45 ft. lbs.).
7. Install the timing belt (Refer to «TIMING BELT AND SPROCKET(S)»(ref-189920-S00531976452005091600000) ).
8. Install the generator mount bracket. see scheme 31
9. Install the generator.
10. Install right engine mount bracket and engine mount (Refer to «INSTALLATION»(ref-189920-S03979579942005091600000) ).
11. Fill the cooling system (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
12. Install the accessory drive belts (Refer to «INSTALLATION»(ref-338220-S02643625932009081800000) ).
13. Lower vehicle and connect battery cable.

1. Inspect the O-ring for damage before installing the tube into the cylinder block (Scheme 43)
2. Lube O-ring with coolant and install inlet tube into the cylinder block opening (Scheme 43)
3. Install the two inlet tube fasteners and tighten to 12 N-m (105 in. lbs.).
4. Connect the radiator lower hose see scheme 12 and heater hose to inlet tube (Scheme 44)
5. Install the radiator upper hose.
6. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).

Scheme 43

Scheme 44

Scheme 45

1. Drain the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).
2. Raise vehicle on hoist and remove the belt splash shield.
3. Remove the radiator lower hose from inlet tube (Scheme 45)
4. Remove the oil cooler outlet/heater return hose from inlet tube (only if equipped with engine oil cooler) see scheme 42
5. Remove the inlet tube bolts see scheme 43
6. Remove the inlet tube see scheme 43 Discard the O-ring seal.

1. Clean the inlet tube O-ring sealing surfaces on the timing cover housing and tube.
2. Apply Mopar® Dielectric Grease or equivalent to the O-ring before installation.
3. Position new O-ring seal on inlet tube see scheme 43
4. Install the inlet tube see scheme 43 Tighten bolts to 28 N-m (250 in. lbs.).
5. Connect radiator lower hose (Scheme 45) and heater return hose (if equipped with engine oil cooler) see scheme 42 to the inlet tube.
6. Install the drive belt splash shield and lower vehicle.
7. Fill the cooling system. (Refer to «STANDARD PROCEDURE»(ref-338220-S01254302102009081800000) ).