Chrysler Voyager Service Manual Gs 1999 1996
http://manualplace.com/download/chrysler-voyager-service-manual-gs-1999-1996/
Chrysler Voyager Service Manual Gs 1999 1996
http://manualplace.com/download/chrysler-voyager-service-manual-gs-1999-1996/
NOPARTOFTHISPUBLICATIONMAYBE REPRODUCED,STOREDINARETRIEVAL SYSTEM,ORTRANSMITTED,INANYFORMOR BYANYMEANS,ELECTRONIC,MECHANICAL, PHOTOCOPYING,RECORDING,OROTHERWISE, WITHOUTTHEPRIORWRITTENPERMISSION OFCHRYSLERINTERNATIONAL.
ChryslerInternationalreservestherighttomakechangesindesignorto makeadditionstoorimprovementsinitsproductswithoutimposinganyobligationsuponitselftoinstallthemonitsproductspreviouslymanufactured.
LithoinU.S.A.Copyright©1976ChryslerCorporation
Theinformationcontainedinthisservicemanualhasbeenpreparedfortheprofessionalautomotivetechnicianinvolvedindailyrepairoperations.Thismanualdoesnotcovertheoryofoperation,whichisaddressed inservicetrainingmaterial.Informationdescribingtheoperationanduseofstandardandoptionalequipment isincludedintheOwner’sManualprovidedwiththevehicle.
Informationinthismanualisdividedintogroups.Thesegroupscontaingeneralinformation,diagnosis, testing,adjustments,removal,installation,disassembly,andassemblyproceduresforthesystemsandcomponents.Toassistinlocatingagrouptitlepage,usetheGroupTabLocatoronthefollowingpage.Thesolidbar afterthegrouptitleisalignedtoasolidtabonthefirstpageofeachgroup.Thefirstpageofthegrouphas acontentssectionthatlistsmajortopicswithinthegroup.IfyouarenotsurewhichGroupcontainstheinformationyouneed,lookuptheComponent/Systeminthealphabeticalindexlocatedintherearofthismanual.
Tighteningtorquesareprovidedasaspecificvaluethroughoutthismanual.Thisvaluerepresentsthe midpointoftheacceptableengineeringtorquerangeforagivenfastenerapplication.Thesetorquevaluesare intendedforuseinserviceassemblyandinstallationproceduresusingthecorrectOEMfasteners.When replacingfasteners,alwaysusethesametype(partnumber)fastenerasremoved.
ChryslerInternationalreservestherighttochangetestingprocedures,specifications,diagnosis,repair methods,orvehiclewiringatanytimewithoutpriornoticeorincurringobligation.
VEHICLESAFETYCERTIFICATIONLABEL
Avehiclesafetycertificationlabel(Fig.1)islocated ontherearshutfaceofthedriver’sdoor.Thislabel indicatesdateofmanufacture(monthandyear), GrossVehicleWeightRating(GVWR),GrossAxle WeightRating(GAWR)front,GrossAxleWeightRating(GAWR)rearandtheVehicleIdentificationNumber(VIN).TheMonth,DayandHourofmanufacture isalsoincluded.
Whenitisnecessarytocontactthemanufacturer regardingserviceorwarranty,theinformationonthe VehicleSafetyCertificationLabelwouldberequired.
Toprotecttheconsumerfromtheftandpossible fraud,themanufacturerisrequiredtoincludea CheckDigitattheninthpositionoftheVehicleIdentificationNumber.Thecheckdigitisusedbythe manufacturerandgovernmentagenciestoverifythe authenticityofthevehicleandofficialdocumentation.Theformulatousethecheckdigitisnot releasedtothegeneralpublic.
TheVehicleIdentificationNumber(VIN)canbe viewedthroughthewindshieldattheupperleftcorneroftheinstrumentpanel,neartheleftwindshield pillar(Fig.2).TheVINconsistsof17charactersina combinationoflettersandnumbersthatprovidespecificinformationaboutthevehicle.RefertoVIN CodeBreakdownChartfordecodinginformation.
TheBodyCodePlate(Fig.3)islocatedinthe enginecompartmentontheradiatorclosurepanel crossmember.Therearesevenlinesofinformationon thebodycodeplate.Lines4,5,6,and7arenotused todefineserviceinformation.Informationreadsfrom lefttoright,startingwithline3inthecenterofthe platetoline1atthebottomoftheplate.
POSITIONINTERPRETATIONCODE=DESCRIPTION
1CountryofOrigin1=UnitedStates
2=Canada
2MakeB=Dodge
C=Chrysler
P=Plymouth
3VehicleType4=MultipurposePass.Vehicle
4GrossVehicleWeightRatingG=2268-2721kg(5001-6000lbs)
5CarLineP=Chrysler,Town&Country
P=Dodge,Caravan/GrandCaravan
P=Plymouth,Voyager/GrandVoyager
T=AWDChrysler,Town&Country
T=AWDDodge,GrandCaravan
T=AWDPlymouth,GrandVoyager
6Series2=FWDCaravan/GrandCaravan,Voyager/ GrandVoyager
4=CaravanSE/GrandCaravanSE,Voyager
SE/GrandVoyagerSE
5=CaravanLEorES/GrandCaravanLEorES, VoyagerLE/GrandVoyagerLE,Town&Country
LX
6=Town&CountryLXI
7BodyStyle4=LongWheelBase
5=ShortWheelBase
8EngineB=2.4L4cyl.MPI16-VALVEDOHC
3=3.0L6cyl.gasMPI
R=3.3L6cyl.gasMPI
L=3.8L6cyl.gasMPI
9CheckDigitSeeexplanationinthissection.
10ModelYearV=1997
11AssemblyPlantB=St.LouisSouth
R=Windsor
12thru17SequenceNumber6digitnumberassignedbyassemblyplant.
BODYCODEPLATE–LINE3
DIGITS1THROUGH12
VehicleOrderNumber
DIGITS13THROUGH17
Openspace
DIGITS18AND19
VehicleShellLine • NS
•
•
•
•
•
•
DIGITS15THROUGH18
InteriorTrimCode
DIGIT19
OpenSpace
DIGITS20,21,AND22
EngineCode
• EDZ=2.4L4cyl.DOHCGasoline
• EFA=3.0L6cyl.Gasoline
• EGA=3.3L6cyl.Gasoline
• EGH=3.8L6cyl.Gasoline
BODYCODEPLATELINE1
DIGITS1,2,AND3
TransaxleCodes
• DGB=31TH3-SpeedAutomaticTransaxle
DIGIT21
PriceClass
• H=Highline
• L=Lowline
• P=Premium
• S=Luxury
DIGITS22AND23
BodyType
• 52=ShortWheelBase
• 53=LongWheelBase
BODYCODEPLATELINE2
DIGITS1,2AND3
Paintprocedure
DIGIT4
OpenSpace
DIGITS5THROUGH8
Primarypaint
SeeGroup23,Bodyforcolorcodes.
DIGIT9
OpenSpace
DIGITS10THROUGH13
SecondaryPaint
DIGIT14
OpenSpace
• DGL=41TE4-speedElectronicAutomaticTransaxle
• DGM=31TH3-SpeedAutomaticTransaxle
DIGIT4
OpenSpace
DIGIT5
MarketCode
• C=Canada
• B=International
• M=Mexico
• U=UnitedStates
DIGIT6
OpenSpace
DIGITS7THROUGH23
VehicleIdentificationNumber
• RefertoVehicleIdentificationNumber(VIN) paragraphforproperbreakdownofVINcode.
IFTWOBODYCODEPLATESAREREQUIRED
ThelastcodeshownoneitherplatewillbefollowedbyEND.Whentwoplatesarerequired,the lastcodespaceonthefirstplatewillindicate(CTD) Whenasecondplateisrequired,thefirstfour spacesofeachlinewillnotbeusedduetooverlapof theplates.
Thegraphicsymbolsillustratedinthefollowing chart(Fig.4)areusedtoidentifyvariousinstrument controls.Thesymbolscorrespondtothecontrolsand displaysthatarelocatedontheinstrumentpanel.
FASTENERIDENTIFICATION
THREADIDENTIFICATION
SAEandmetricbolt/nutthreadsarenotthesame. ThedifferenceisdescribedintheThreadNotation chart(Fig.5).
TheSAEboltstrengthgradesrangefromgrade2 tograde8.Thehigherthegradenumber,thegreater theboltstrength.Identificationisdeterminedbythe linemarksonthetopofeachbolthead.Theactual
boltstrengthgradecorrespondstothenumberofline marksplus2.Themostcommonlyusedmetricbolt strengthclassesare9.8and12.9.Themetricstrength classidentificationnumberisimprintedontheheadof thebolt.Thehighertheclassnumber,thegreaterthe boltstrength.Somemetricnutsareimprintedwitha single-digitstrengthclassonthenutface.Refertothe FastenerIdentificationandFastenerStrengthCharts.
Fig.4WARNING:USEOFANINCORRECTFASTENER MAYRESULTINCOMPONENTDAMAGEORPERSONALINJURY.
Figureart,specificationsandtorquereferencesin thisServiceManualareidentifiedinmetricandSAE format.
Duringanymaintenanceorrepairprocedures,itis importanttosalvagemetricfasteners(nuts,bolts, etc.)forreassembly.Ifthefastenerisnotsalvageable,afastenerofequivalentspecificationshouldbe used.
Themetricsystemisbasedonquantitiesofone, ten,onehundred,onethousandandonemillion(Fig. 6).
Thefollowingchartwillassistinconvertingmetric unitstoequivalentEnglishandSAEunits,orvise versa.
RefertotheConversionCharttoconverttorque valueslistedinmetricNewton-meters(N·m).Also, usethecharttoconvertbetweenmillimeters(mm) andinches(in.)
IndividualTorqueChartsappearattheendof manyGroups.RefertotheStandardTorqueSpecificationsChartfortorquereferencesnotlistedinthe individualtorquecharts.
Fig.6MetricPrefixesGENERALINFORMATION
GENERALINFORMATION
E-MARKLABEL
AnE-markLabel(Fig.1)islocatedontherear shutfaceofthedriver’sdoor.Thelabelcontainsthe followinginformation:
• DateofManufacture
• Month-Day-Hour(MDH)
• VehicleIdentificationNumber(VIN)
• CountryCodes
• RegulationNumber
• RegulationAmendmentNumber
• ApprovalNumber
Toprotecttheconsumerfromtheftandpossible fraudthemanufacturerisrequiredtoincludeacheck DigitattheninthpositionoftheVIN.Thecheck digitisusedbythemanufacturerandgovernment agenciestoverifytheauthenticityofthevehicleand officialdocumentation.Theformulatousethecheck digitisnotreleasedtothegeneralpublic.
TheVehicleIdentificationNumber(VIN)canbe viewedthroughthewindshieldattheupperleftcorneroftheinstrumentpanelnexttotheleftA-pillar (Fig.2).TheVINconsistsof17charactersinacombinationoflettersandnumbersthatprovidespecific informationaboutthevehicle.RefertotheVIN DecodingInformationTabletointerpretVINcode.
TheBodyCodePlateislocated(Fig.3)inthe enginecompartmentontheradiatorclosurepanel crossmember.Therearesevenlinesofinformationon thebodycodeplate.Lines4,5,6,and7arenotused todefineserviceinformation.Informationreadsfrom lefttoright,startingwithline3inthecenterofthe platetoline1atthebottomoftheplate.
BODYCODEPLATE—LINE3
DIGITS1THROUGH12
VehicleOrderNumber
DIGITS13,14,AND15
OpenSpace
POSITIONINTERPRETATIONCODE=DESCRIPTION
1Countryoforigin1=UnitedStatesorAustria
2=Canada
2MakeC=Chrysler
D=Dodge
3VehicleType4=MultipurposePass.Veh.
4GrossVehicleWeightRatingG=2268-2721kg(5001-6000lbs)
5CarLineC=Voyager/GrandVoyagerAWD
Y=Voyager/GrandVoyagerFWD
6Series4=Voyager/GrandVoyagerSEFWD
5=Voyager/GrandVoyagerLEFWD/AWD
6=VoyagerLXFWD/AWD
N=5-SpeedManualTransmission
B=4-SpeedAutomaticTransmission
7BodyStyle2=ShortWheelbase4-Door
3=ShortWheelbase3-Door
4=LongWheelbasePremium4-Door
5=LongWheelbaseHighline4-door
7=ShortWheelbaseCommercialVan
8EngineB=2.4L4cyl.MPI16-ValveDOHC
C=2.0L4cyl.MPI16-ValveSOHC
M=2.5L4cylTurboDiesel(Intercooler)
R=3.3L6cyl.gasMPI
L=3.8L6cyl.gasMPI
9CheckDigitSeeexplanationinthissection.
10ModelYearW=1998
11AssemblyPlantB=St.LouisSouth,U.S.A.
R=Windsor,Canada
U=Graz,Austria
12BuildSequence6Digitnumberassignedbyassemblyplant
DIGITS16,17,AND18
VehicleShellCarLine
• GSYH=Voyager/GrandVoyagerSEFWD
• GSYP=Voyager/GrandVoyagerLEFWD
• GSYS=VoyagerLXFWD
• GSCP=Voyager/GrandVoyagerLEAWD
• GSCS=VoyagerLXAWD
DIGIT19
PriceClass
• H=HighLine
• P=Premium
• S=Special/Sport
DIGITS20AND21
BodyType
• 52=ShortWheelBase
• 53=LongWheelBase
BODYCODEPLATE—LINE2
DIGITS1,2,AND3
PaintProcedure
DIGIT4
OpenSpace
DIGIT4
OpenSpace
DIGIT5
MarketCode
• B=International
• M=Mexico
DIGIT6
OpenSpace
DIGITS7THROUGH23
VehicleIdentificationNumber(VIN)
RefertoVehicleIdentificationNumber(VIN)paragraphforproperbreakdownofVINcode.
IFTWOBODYCODEPLATESAREREQUIRED
DIGITS5THROUGH8
PrimaryPaint
SeeGroup23,Bodyforcolorcodes.
DIGIT9
OpenSpace
DIGITS10THROUGH13
SecondaryPaint
DIGIT14
OpenSpace
DIGITS15THROUGH18
InteriorTrimCode
DIGIT19
OpenSpace
DIGITS20,21,AND22
EngineCode
• ECB=2.0L4cyl16valveSOHCgasoline
• EDZ=2.4L4cyl.16valveDOHCgasoline
• ENC=2.5L4cyl.TurboDiesel(Intercooler)
• EGA=3.3L6cyl.gasoline
• EGH=3.8L6cyl.gasoline
BODYCODEPLATELINE1
DIGITS1,2,AND3
TransaxleCodes
• DGL=41TE4-speedElectronicAutomaticTransaxle
• DD3=A-5985–speedManualTransaxle
ThelastcodeshownoneitherplatewillbefollowedbyEND.Whentwoplatesarerequired,the lastcodespaceonthefirstplatewillindicatecontinued(CTD).
Whenasecondplateisrequired,thefirstfour spacesofeachlinewillnotbeusedduetooverlapof theplates.
TheManufacturerPlate(Fig.4)islocatedinthe enginecompartmentontheradiatorclosurepanel crossmemberadjacenttotheBodyCodePlate.The platecontainsfivelinesofinformation:
1.VehicleIdentificationNumber(VIN)
2.GrossVehicleMass(GVM)
3.GrossTrainMass(GTM)
4.GrossFrontAxleRating(GFAR)
5.GrossRearAxleRating(GRAR)
Fig.3BodyCodePlateServiceandmaintenanceproceduresforcomponentsandsystemslistedinSchedule–AorBcanbe foundbyusingtheGroupTabLocatorindexatthe frontofthismanual.Ifitisnotclearwhichgroup containstheinformationneeded,refertotheindexat thebackofthismanual.
Therearetwomaintenanceschedulesthatshow properservicebasedontheconditionsthatthevehicleissubjectedto.
Schedule– A,listsscheduledmaintenancetobe performedwhenthevehicleisusedforgeneraltransportation.
Schedule– B,listsmaintenanceintervalsforvehiclesthatareoperatedundertheconditionslistedat thebeginningoftheMaintenanceSchedulesection.
Usetheschedulethatbestdescribesyourdriving conditions.
Wheretimeandmileagearelisted,followthe intervalthatoccursfirst.
Whenserviceisrequired,ChryslerCorporation recommendsthatonlyMopar brandparts,lubricantsandchemicalsbeused.Moparprovidesthe bestengineeredproductsforservicingChryslerCorporationvehicles.
ChryslerCorporationusesinternationalsymbolsto identifyenginecompartmentlubricantandfluid inspectionandfilllocations(Fig.1).
Onlylubricantsthatareendorsedbythefollowing organizationshouldbeusedtoserviceaChrysler Corporationvehicle.
• SocietyofAutomotiveEngineers(SAE)
• AmericanPetroleumInstitute(API)(Fig.2)
• NationalLubricatingGreaseInstitute(NLGI) (Fig.3)
AnSAEviscositygradeisusedtospecifytheviscosityofengineoil.SAE30specifiesasingleviscosityengineoil.Engineoilsalsohavemultiple viscosities.ThesearespecifiedwithadualSAEviscositygradewhichindicatesthecold-to-hottemperatureviscosityrange.
• SAE30=singlegradeengineoil.
• SAE10W-30=multiplegradeengineoil.
TheAPIServiceGradespecifiesthetypeofperformancetheengineoilisintendedtoprovide.TheAPI ServiceGradespecificationsalsoapplytoenergyconservingengineoils.
UseengineoilsthatareAPIServiceCertified. 5W-30and10W-30MOPARengineoilsconformto specifications.
RefertoGroup9,Engineforengineoilspecification.
SAEratingsalsoapplytomultiplegradegear lubricants.Inaddition,APIclassificationdefinesthe lubricantsusage.
Lubricatinggreaseisratedforqualityandusage bytheNLGI.AllapprovedproductshavetheNLGI symbol(Fig.3)onthelabel.AtthebottomNLGI symbolistheusageandqualityidentificationletters. Wheelbearinglubricantisidentifiedbytheletter “G”.Chassislubricantisidentifiedbythelatter“L”. Theletterfollowingtheusageletterindicatesthe qualityofthelubricant.Thefollowingsymbolsindicatethehighestquality.
ServiceandmaintenanceproceduresforcomponentsandsystemslistedinSchedule–AorBcanbe foundbyusingtheGroupTabLocatorindexatthe frontofthismanual.Ifitisnotclearwhichgroup containstheinformationneeded,refertotheindexat thebackofthismanual.
Therearetwomaintenanceschedulesthatshow properservicebasedontheconditionsthatthevehicleissubjectedto.
Schedule– A,listsscheduledmaintenancetobe performedwhenthevehicleisusedforgeneraltransportation.
Schedule– B,listsmaintenanceintervalsforvehiclesthatareoperatedundertheconditionslistedat thebeginningoftheMaintenanceSchedulesection.
Usetheschedulethatbestdescribesyourdriving conditions.
Wheretimeandmileagearelisted,followthe intervalthatoccursfirst.
• Checkengineoillevel,addasrequired.
• Checkwindshieldwashersolventandaddif required.
• Checktirepressureandlookforunusualwear ordamage.
• Inspectbatteryandcleanandtightenterminals asrequired.
• Checkfluidlevelsofcoolantreservoir,brake mastercylinder,powersteeringandtransaxleand addasneeded.
• Checkalllightsandallotherelectricalitemsfor correctoperation.
• Checkrubbersealsoneachsideoftheradiator forproperfit.
• Inspectexhaustsystem.
• Inspectbrakehoses
• InspecttheCVjointsandfrontsuspensioncomponents
• Rotatethetiresateachoilchangeinterval shownonSchedule–A(7,500miles)oreveryother intervalshownonSchedule–B(6,000miles).
• Checkthecoolantlevel,hoses,andclamps.
• Ifyourmileageislessthan7,500miles(12000 km)yearly,replacetheengineoilfilterateachoil change.
• Replaceengineoilfilteron2.4Lengines.
7,500Miles(12000km)orat6months
• Changeengineoil.
15,000Miles(24000km)orat12months
• Changeengineoil.
• Replaceengineoilfilter.
22,500Miles(36000km)orat18months
• Changeengineoil.
• Inspectbrakelinings.
30,000Miles(48000km)orat24months
• Changeengineoil.
• Changeautomatictransmissionfluid.
• Replaceengineoilfilter.
• Replaceaircleanerelement.
• Inspecttierodendsandbootseals.
37,500Miles(60000km)orat30months
• Changeengineoil.
45,000Miles(72000km)orat36months
• Changeengineoil.
• Replaceengineoilfilter.
• Inspectbrakelinings.
• Flushandreplaceenginecoolantat36months, regardlessofmileage.
Chrysler Voyager Service Manual Gs 1999 1996
52,500Miles(84000km)orat42months
• Changeengineoil.
• Flushandreplaceenginecoolantifnotdoneat 36months.
60,000Miles(96000km)orat48months
• Changeengineoil.
• Replaceengineoilfilter.
• Replaceaircleanerelement.
• CheckPCVvalveandreplace,ifnecessary. *
• Inspectserpentinedrivebelt,replaceifnecessary.
• Inspecttierodendsandbootseals.
67,500Miles(108000km)orat54months
• Changeengineoil.
• Inspectbrakelinings.
75,000Miles(120000km)orat60months
• Changeengineoil.
• Replaceengineoilfilter.
• Inspectserpentinedrivebelt,replaceifnecessary.Thismaintenanceisnotrequiredifbeltwas previouslyreplaced.
• Flushandreplaceenginecoolantifithasbeen 30,000miles(48000km)or24monthssincelast change.
82,500Miles(132000km)orat66months
• Changeengineoil.
• Flushandreplaceenginecoolantifithasbeen 30,000miles(48000km)or24monthssincelast change.
90,000Miles(144000km)orat72months
• Changeengineoil.
• Replaceengineoilfilter.
• Replaceaircleanerelement.
• CheckPCVvalveandreplace,ifnecessary. Notrequiredifpreviouslychanged.*
• Inspectserpentinedrivebelt,replaceifnecessary.Thismaintenanceisnotrequiredifbeltwas previouslyreplaced.
• Inspecttierodendsandbootseals.
• Inspectbrakelinings.
97,500Miles(156000km)orat78months
• Changeengineoil.
100,000Miles(160,000km)
• Replacesparkplugson3.3Land3.8L engines.
• Replaceignitioncableson3.3Land3.8L engines.
105,000Miles(168000km)orat84months
• Changeengineoil.
• Replaceengineoilfilter.
• Inspectserpentinedrivebelt,replaceifnecessary.Thismaintenanceisnotrequiredifbeltwas previouslyreplaced.
• Flushandreplaceenginecoolantifithasbeen 30,000miles(48000km)or24monthssincelast change.
112,500Miles(180000km)orat90months
• Changeengineoil.
• Inspectbrakelinings.
• Flushandreplaceenginecoolantifithasbeen 30,000miles(48000km)or24monthssincelast change.
120,000Miles(192000km)orat96months
• Changeengineoil.
• Replaceengineoilfilter.
• Replaceautomatictransmissionfluid.
• Replaceengineaircleanerelement.
• CheckandreplacePCVvalve,ifnecessary. *
• Inspectserpentinedrivebelt.Notrequiredif replacedat75,000,90,000or105,000miles.
• Inspecttierodendsandbootseals.
*ThismaintenanceisrecommendedbyChryslerto theownerbutisnotrequiredtomaintainthewarrantyonthePCVvalve.
**IfCaliforniavehicle,thismaintenanceisrecommendedbyChryslertotheownerbutisnotrequired tomaintainthewarrantyofthetimingbelt.
3,000Miles(5000km)
• Changeengineoil.
6,000Miles(10000km)
• Changeengineoil.
• Replaceengineoilfilter.
9,000Miles(14000km)
• Changeengineoil.
• Inspectbrakelinings.
12,000Miles(19000km)
• Changeengineoil.
• Replaceengineoilfilter.
15,000Miles(24000km)
• Changeengineoil.
• Inspectaircleanerelement.Replaceas necessary.