Chrysler Voyager Service Manual Gs 1999 1996

Page 1

Chrysler Voyager Service Manual Gs 1999 1996

http://manualplace.com/download/chrysler-voyager-service-manual-gs-1999-1996/

CHRYSLER INTERNATIONAL SERVICEMANUAL 1998 CHRYSLERVOYAGER

NOPARTOFTHISPUBLICATIONMAYBE REPRODUCED,STOREDINARETRIEVAL SYSTEM,ORTRANSMITTED,INANYFORMOR BYANYMEANS,ELECTRONIC,MECHANICAL, PHOTOCOPYING,RECORDING,OROTHERWISE, WITHOUTTHEPRIORWRITTENPERMISSION OFCHRYSLERINTERNATIONAL.

ChryslerInternationalreservestherighttomakechangesindesignorto makeadditionstoorimprovementsinitsproductswithoutimposinganyobligationsuponitselftoinstallthemonitsproductspreviouslymanufactured.

LithoinU.S.A.Copyright©1976ChryslerCorporation

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FOREWORD

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.

GROUPTABLOCATOR Introduction 0 LubricationandMaintenance 2 Suspension 5 Brakes 6 Clutch 7 CoolingSystem 8A Battery 8B StartingSystem 8E InstrumentPanelandSystems 8H VehicleSpeedControlSystem 8K WiperandWasherSystems 8L Lamps 8Q VehicleTheft/SecuritySystems 8U ChimeWarning/ReminderSystem 8W WiringDiagrams 9 Engine 13 FrameandBumpers 14 FuelSystem—2.5LDieselEngine/2.0LGasEngine 19 Steering 21 A—598ManualTransaxle 23 Body 24 HeatingandAirConditioning 25 EmissionControlSystem

GENERALINFORMATION

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.

VINCHECKDIGIT

Toprotecttheconsumerfromtheftandpossible fraud,themanufacturerisrequiredtoincludea CheckDigitattheninthpositionoftheVehicleIdentificationNumber.Thecheckdigitisusedbythe manufacturerandgovernmentagenciestoverifythe authenticityofthevehicleandofficialdocumentation.Theformulatousethecheckdigitisnot releasedtothegeneralpublic.

BODYCODEPLATE LOCATIONANDDECODING

VEHICLEIDENTIFICATIONNUMBER

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.

INTRODUCTION CONTENTS pagepage GENERALINFORMATION BODYCODEPLATE ......................1 FASTENERIDENTIFICATION ................4 INTERNATIONALVEHICLECONTROLAND DISPLAYSYMBOLS .....................4 METRICSYSTEM ........................7 TORQUEREFERENCES ...................7 VEHICLEIDENTIFICATIONNUMBER ..........1 VEHICLESAFETYCERTIFICATIONLABEL .....1 VINCHECKDIGIT ........................1
Fig.1VehicleSafetyCertificationLabel
NS INTRODUCTION1
Fig.2VehicleIdentificationNumber(VINPlate)

GENERALINFORMATION(Continued)

VINCODEBREAKDOWNCHART

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

DIGIT20 Carline FWD
H=Plymouth
K=Dodge
S=Chrysler AWD
C=Chrysler
D=Dodge
P=Plymouth
2INTRODUCTION NS

GENERALINFORMATION(Continued)

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.

NS INTRODUCTION3
Fig.3BodyCodePlate

GENERALINFORMATION(Continued)

INTERNATIONALCONTROLANDDISPLAYSYMBOLS

INTERNATIONALVEHICLECONTROLANDDISPLAY SYMBOLSINTERNATIONALVEHICLECONTROL ANDDISPLAYSYMBOLS

Thegraphicsymbolsillustratedinthefollowing chart(Fig.4)areusedtoidentifyvariousinstrument controls.Thesymbolscorrespondtothecontrolsand displaysthatarelocatedontheinstrumentpanel.

FASTENERIDENTIFICATION

FASTENERIDENTIFICATION

THREADIDENTIFICATION

SAEandmetricbolt/nutthreadsarenotthesame. ThedifferenceisdescribedintheThreadNotation chart(Fig.5).

GRADE/CLASSIDENTIFICATION

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.4
4INTRODUCTION NS
Fig.5ThreadNotation—SAEandMetric
FASTENERIDENTIFICATION NS INTRODUCTION5 GENERALINFORMATION(Continued)
6INTRODUCTION NS GENERALINFORMATION(Continued)
FASTENERSTRENGTH

GENERALINFORMATION(Continued)

METRICSYSTEM

WARNING: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.)

CONVERSIONFORMULASANDEQUIVALENTVALUES

TORQUEREFERENCES

IndividualTorqueChartsappearattheendof manyGroups.RefertotheStandardTorqueSpecificationsChartfortorquereferencesnotlistedinthe individualtorquecharts.

Fig.6MetricPrefixes
NS INTRODUCTION7
8INTRODUCTION NS GENERALINFORMATION(Continued)
METRICCONVERSION

TORQUESPECIFICATIONS

NS INTRODUCTION9 GENERALINFORMATION(Continued)

GENERALINFORMATION

GENERALINFORMATION

E-MARKLABEL

AnE-markLabel(Fig.1)islocatedontherear shutfaceofthedriver’sdoor.Thelabelcontainsthe followinginformation:

• DateofManufacture

• Month-Day-Hour(MDH)

• VehicleIdentificationNumber(VIN)

• CountryCodes

• RegulationNumber

• RegulationAmendmentNumber

• ApprovalNumber

VINCHECKDIGIT

Toprotecttheconsumerfromtheftandpossible fraudthemanufacturerisrequiredtoincludeacheck DigitattheninthpositionoftheVIN.Thecheck digitisusedbythemanufacturerandgovernment agenciestoverifytheauthenticityofthevehicleand officialdocumentation.Theformulatousethecheck digitisnotreleasedtothegeneralpublic.

BODYCODEPLATE

LOCATIONANDDECODING

VEHICLEIDENTIFICATIONNUMBER

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

INTRODUCTION CONTENTS pagepage
BODYCODEPLATE ......................1 E-MARKLABEL .........................1 MANUFACTURERPLATE ..................3 VEHICLEIDENTIFICATIONNUMBER .........1
Fig.1E-MarkLabel
NS/GS INTRODUCTION1
Fig.2VINPLATELOCATION

GENERALINFORMATION(Continued)

VINDECODINGINFORMATION

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

NS/GS
2INTRODUCTION

GENERALINFORMATION(Continued)

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.

MANUFACTURERPLATE

TheManufacturerPlate(Fig.4)islocatedinthe enginecompartmentontheradiatorclosurepanel crossmemberadjacenttotheBodyCodePlate.The platecontainsfivelinesofinformation:

1.VehicleIdentificationNumber(VIN)

2.GrossVehicleMass(GVM)

3.GrossTrainMass(GTM)

4.GrossFrontAxleRating(GFAR)

5.GrossRearAxleRating(GRAR)

Fig.3BodyCodePlate
INTRODUCTION3
Fig.4ManufacturerPlate
NS/GS

GENERALINFORMATION INTRODUCTION

ServiceandmaintenanceproceduresforcomponentsandsystemslistedinSchedule–AorBcanbe foundbyusingtheGroupTabLocatorindexatthe frontofthismanual.Ifitisnotclearwhichgroup containstheinformationneeded,refertotheindexat thebackofthismanual.

Therearetwomaintenanceschedulesthatshow properservicebasedontheconditionsthatthevehicleissubjectedto.

Schedule– A,listsscheduledmaintenancetobe performedwhenthevehicleisusedforgeneraltransportation.

Schedule– B,listsmaintenanceintervalsforvehiclesthatareoperatedundertheconditionslistedat thebeginningoftheMaintenanceSchedulesection.

Usetheschedulethatbestdescribesyourdriving conditions.

Wheretimeandmileagearelisted,followthe intervalthatoccursfirst.

PARTSANDLUBRICANTRECOMMENDATIONS

Whenserviceisrequired,ChryslerCorporation recommendsthatonlyMopar brandparts,lubricantsandchemicalsbeused.Moparprovidesthe bestengineeredproductsforservicingChryslerCorporationvehicles.

INTERNATIONALSYMBOLS

ChryslerCorporationusesinternationalsymbolsto identifyenginecompartmentlubricantandfluid inspectionandfilllocations(Fig.1).

CLASSIFICATIONOFLUBRICANTS

Onlylubricantsthatareendorsedbythefollowing organizationshouldbeusedtoserviceaChrysler Corporationvehicle.

• SocietyofAutomotiveEngineers(SAE)

• AmericanPetroleumInstitute(API)(Fig.2)

• NationalLubricatingGreaseInstitute(NLGI) (Fig.3)

CONTENTS pagepage GENERALINFORMATION ...................1 JUMPSTARTING,HOISTINGANDTOWING ....7 MAINTENANCESCHEDULES ................3 GENERALINFORMATION INDEX pagepage GENERALINFORMATION CLASSIFICATIONOFLUBRICANTS ...........1 FLUIDCAPACITIES .......................2 INTERNATIONALSYMBOLS ................1 INTRODUCTION .........................1 PARTSANDLUBRICANT RECOMMENDATIONS ....................1
LUBRICATIONANDMAINTENANCE
NS LUBRICATIONANDMAINTENANCE0-1
Fig.1InternationalSymbols

ENGINEOIL

SAEVISCOSITYRATINGINDICATESENGINEOILVISCOSITY

AnSAEviscositygradeisusedtospecifytheviscosityofengineoil.SAE30specifiesasingleviscosityengineoil.Engineoilsalsohavemultiple viscosities.ThesearespecifiedwithadualSAEviscositygradewhichindicatesthecold-to-hottemperatureviscosityrange.

• SAE30=singlegradeengineoil.

• SAE10W-30=multiplegradeengineoil.

APIQUALITYCLASSIFICATION

TheAPIServiceGradespecifiesthetypeofperformancetheengineoilisintendedtoprovide.TheAPI ServiceGradespecificationsalsoapplytoenergyconservingengineoils.

UseengineoilsthatareAPIServiceCertified. 5W-30and10W-30MOPARengineoilsconformto specifications.

RefertoGroup9,Engineforengineoilspecification.

GEARLUBRICANTS

SAEratingsalsoapplytomultiplegradegear lubricants.Inaddition,APIclassificationdefinesthe lubricantsusage.

LUBRICANTSANDGREASES

Lubricatinggreaseisratedforqualityandusage bytheNLGI.AllapprovedproductshavetheNLGI symbol(Fig.3)onthelabel.AtthebottomNLGI symbolistheusageandqualityidentificationletters. Wheelbearinglubricantisidentifiedbytheletter “G”.Chassislubricantisidentifiedbythelatter“L”. Theletterfollowingtheusageletterindicatesthe qualityofthelubricant.Thefollowingsymbolsindicatethehighestquality.

FLUIDCAPACITIES

FuelTank .......................76L(20 gal.) EngineOil,WithFilter ........... .4.3L(4.5qts.) EngineOil,W/OFilter .3.8L(4.0qts.) CoolingSystem2.4LEngine .9.0L(9.5qts.) CoolingSystem3.OLEngine ...... .9.5L(10.5qts.) CoolingSystem3.3or3.8LEngine..9.5L(10.5qts.) AutomaticTransaxleServiceFill .3.8L(4.0qts.) AutomaticTransaxle 31TH/O-haulFill .8.0L(8.5qts.) AutomaticTransaxle 41TE/O-haulFill .............. .8.6L(9.1qts.) PowerSteering ................ .0.81L(1.7pts.)
Fig.2APISymbol Fig.3NLGISymbol
0-2LUBRICATIONANDMAINTENANCE NS GENERALINFORMATION(Continued)

GENERALINFORMATION INTRODUCTION

ServiceandmaintenanceproceduresforcomponentsandsystemslistedinSchedule–AorBcanbe foundbyusingtheGroupTabLocatorindexatthe frontofthismanual.Ifitisnotclearwhichgroup containstheinformationneeded,refertotheindexat thebackofthismanual.

Therearetwomaintenanceschedulesthatshow properservicebasedontheconditionsthatthevehicleissubjectedto.

Schedule– A,listsscheduledmaintenancetobe performedwhenthevehicleisusedforgeneraltransportation.

Schedule– B,listsmaintenanceintervalsforvehiclesthatareoperatedundertheconditionslistedat thebeginningoftheMaintenanceSchedulesection.

Usetheschedulethatbestdescribesyourdriving conditions.

Wheretimeandmileagearelisted,followthe intervalthatoccursfirst.

UNSCHEDULEDINSPECTION

AtEachStopforFuel

• Checkengineoillevel,addasrequired.

• Checkwindshieldwashersolventandaddif required.

OnceaMonth

• Checktirepressureandlookforunusualwear ordamage.

• Inspectbatteryandcleanandtightenterminals asrequired.

• Checkfluidlevelsofcoolantreservoir,brake mastercylinder,powersteeringandtransaxleand addasneeded.

• Checkalllightsandallotherelectricalitemsfor correctoperation.

• Checkrubbersealsoneachsideoftheradiator forproperfit.

AtEachOilChange

• 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.

SCHEDULE–A

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.

MAINTENANCESCHEDULES INDEX pagepage GENERALINFORMATION INTRODUCTION .........................3 SCHEDULE–A ..........................3 SCHEDULE–B ..........................4 UNSCHEDULEDINSPECTION ...............3
NS LUBRICATIONANDMAINTENANCE0-3

Chrysler Voyager Service Manual Gs 1999 1996

GENERALINFORMATION(Continued)

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.

SCHEDULE–B

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.

0-4LUBRICATIONANDMAINTENANCE NS
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