Chrysler RG Voyager. Manual — part 461
INSTALLATION
ACCESSORY DRIVE BELT
(1) Install the accessory drive belt in proper posi-
tion (Fig. 8).
(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).
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. 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
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
7a - 12
ACCESSORY DRIVE
RG
DRIVE BELTS (Continued)
ENGINE
TABLE OF CONTENTS
page
page
COOLANT
. . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - COOLANT
. . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . 15
COOLANT RECOVERY PRESS CONTAINER
. . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE COOLANT TEMP SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE COOLANT THERMOSTAT
. . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 19
RADIATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 20
RADIATOR DRAINCOCK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . 21
WATER PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION - WATER PUMP HOUSING
RADIATOR PRESSURE CAP
. . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - PRESSURE
RELIEF TEST . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . 25
RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - RADIATOR FAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . 26
HOSE CLAMPS
RADIATOR FAN RELAY
. . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . 27
COOLANT SYSTEM HOSES
INSTALLATION - UPPER RADIATOR HOSE
INSTALLATION - LOWER RADIATOR HOSE
INSTALLATION - COOLANT BYPASS HOSE
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 oper-
ating conditions. The recommended mixture of 50/50
ethylene-glycol and water will provide protection
against freezing to -37 ° C (-35 ° F). The antifreeze
concentration must always be a minimum of 44 per-
cent, year-round in all climates. If percentage is
lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
RG
ENGINE
7a - 13
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 ° C (-90 ° F). A
higher percentage will freeze at a warmer tempera-
ture. 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 for-
mation of additive deposits in the system, as the cor-
rosion 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 ° C (300 ° F). This temperature is hot enough to
melt plastic and soften solder. The increased temper-
ature can result in engine detonation. In addition,
100 percent ethylene-glycol freezes at -22 ° C (-8 ° 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 ethyl-
ene-glycol. The freeze point of 50/50 propylene-glycol
and water is -32 ° C (-26 ° F). 5 ° C higher than eth-
ylene-glycol’s freeze point. The boiling point (protec-
tion against summer boil-over) of propylene-glycol is
125 ° C (257 ° F ) at 96.5 kPa (14 psi), compared to
128 ° C (263 ° F) for ethylene-glycol. Use of propy-
lene-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 inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-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 concentra-
tion.
A hydrometer will test the amount of glycol in a
mixture by measuring the specific gravity of the mix-
ture. 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 gly-
cols into their coolant formulations. Propylene glycol
is the most common new coolant. However, propylene
glycol based coolants do not provide the same freez-
ing protection and corrosion protection and is not rec-
ommended.
CAUTION: Do not mix types of coolant, corrosion
protection will be severely reduced.
STANDARD PROCEDURE
COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
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 recommended antifreeze/cool-
ant type (Refer to LUBRICATION & MAINTE-
NANCE/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
recommended
antifreeze/coolant
type
(Refer
to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
7a - 14
ENGINE
RG
COOLANT (Continued)
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.
COOLING SYSTEM FILLING
(1) Remove pressure vent cap from coolant recov-
ery pressure container.
(2) Loosen air bleed screw on the thermostat hous-
ing.
(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 con-
tainer until level reaches the full line.
(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.
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 - AIR FILTER HOUSING
9 - ENGINE OIL FILL 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
RG
ENGINE
7a - 15
COOLANT (Continued)
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