Chrysler RG Voyager. Manual — part 463

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 - COOL-

ING/ENGINE/COOLANT

-

STANDARD

PROCE-

DURE).

(4) Remove the radiator fans. (Refer to 7 - COOL-

ING/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 con-
denser from the radiator by lifting upward to disen-
gage

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.

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.

Fig. 11 UPPER AND LOWER RADIATOR HOSES -

2.5L DIESEL SHOWN

1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET

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

7a - 20

ENGINE

RG

RADIATOR (Continued)

RADIATOR DRAINCOCK

REMOVAL

CAUTION: Use of pliers on draincock is not recom-
mended. Damage may occur to radiator or drain-
cock.

NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.

(1) Drain the cooling system (Refer to 7 - COOL-

ING/ENGINE/COOLANT

-

STANDARD

PROCE-

DURE).

(2) Open the draincock by turning it counterclock-

wise until it stops.

(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 13) from the radiator

tank.

INSTALLATION

(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
(3) Tighten the draincock by turning clockwise

until it stops.

(4) Fill the cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

WATER PUMP

DESCRIPTION

The water pump on the 2.5L CRD diesel has a die

cast aluminum housing. It bolts to a aluminum hous-
ing which attaches to the engine block (Fig. 14).

OPERATION

The water pump is used to circulate coolant

through the cooling system. The coolant is pumped
through the engine block, cylinder head, heater core,
EGR cooler, cabin heater, and radiator.

Fig. 13 Draincock

1 - RADIATOR TANK
2 - DRAINCOCK

Fig. 14 WATER PUMP

1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK

RG

ENGINE

7a - 21

REMOVAL

REMOVAL - WATER PUMP

(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(3) Remove timing belt inner and outer covers

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).

(4) Remove water pump retaining bolts and pump

(Fig. 15).

REMOVAL - WATER PUMP HOUSING

(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(3) Remove both outer and inner timing belt covers

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).

(4) Disconnect water pump housing to thermostat

housing bypass hose (Fig. 16).

(5) Remove the water pump housing retaining

nuts (Fig. 17).

(6) Remove water pump housing from engine block

(Fig. 17).

CLEANING

Clean gasket mating surfaces as necessary.

INSTALLATION

INSTALLATION - WATER PUMP

(1) Clean gasket mating surfaces as necessary.
(2) Place water pump and gasket in place. Install

water pump retaining bolts (Fig. 15). Torque bolts to
24.4N·m.

(3) Install both inner and outer timing belt covers

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).

(4) Refill cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(5) Connect negative battery cable.

INSTALLATION - WATER PUMP HOUSING

(1) Clean mating 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).

Fig. 15 WATER PUMP LOCATION

1 - CYLINDER HEAD
2 - ENGINE BLOCK
3 - OIL COOLER
4 - OIL FILTER HOUSING
5 - WATER PUMP

Fig. 16 THERMOSTAT HOUSING LOCATION

1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4 - WATER PUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - EGR VALVE

7a - 22

ENGINE

RG

WATER PUMP (Continued)

(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 pressure container. The cap construction
includes; stainless steel swivel top, rubber seals, and
retainer, main spring, and a spring loaded valve (Fig.
19).

OPERATION

The cooling system is equipped with a pressure cap

that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).

The cooling system will operate at higher than

atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.

There is also a vent valve in the center of the cap.

This valve also opens when coolant is cooling and
contracting, allowing the air to return to the coolant
pressure container. If valve is stuck shut, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 19) and inspect cool-
ant recovery hose routing, to ensure proper
sealing when boiling point is reached.

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 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK

Fig. 18 WATER PUMP HOUSING O-RING

1 - WATER PUMP
2 - WATER PUMP HOUSING O-RING
3 - WATER PUMP HOUSING

Fig. 19 Cooling System Pressure Cap Filler Neck

1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - PRESSURE BOTTLE
8 - FILLER NECK

RG

ENGINE

7a - 23

WATER PUMP (Continued)