1996 CHRYSLER VOYAGER engine oil

²Check drive belt tension.
²Check glow plug operation.
30 000 KM
²Change engine oil.
²Change engine oil filter.
40 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
²Replace fuel filter/water separator element.**
50 000 KM
²Change engine oil.
²Change engine oil filter.
60 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check glow plug operation.
²Replace drive belt.
²Check engine smoke.
²Replace engine coolant.
70 000 KM
²Change engine oil.
²Change engine oil filter.
80 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
²Replace fuel filter/water separator element.**
90 000 KM
²Change engine oil.
²Change engine oil filter.
100 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
EVERY 40 000 KM AFTER 80 000 KM
²Replace fuel filter/water separator element.**
**The fuel filter/water separator element should be
replaced once a year if the vehicle is driven less than
40 000 km annually or if power loss from fuel star-
vation is detected.
EVERY 10 000 KM AFTER 100 000 KM
²Change engine oil.
²Change engine oil filter.
EVERY 20 000 KM AFTER 100 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
SCHEDULEÐB (DIESEL)
500 KM
²Check correct torque, intake manifold mounting
nuts.
²Check correct torque, exhaust manifold mount-
ing nuts.
²Check correct torque, turbocharger mounting
nuts.
²Check correct torque, water manifold bolts.
1 000 KM
²Change engine oil.
²Change engine oil filter.
²Check all fluid levels.
5 000 KM
²Change engine oil.
²Change engine oil filter.
10 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
15 000 KM
²Change engine oil.
²Change engine oil filter.
20 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
25 000 KM
²Change engine oil.
²Change engine oil filter.
30 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
NS/GSLUBRICATION AND MAINTENANCE 0 - 3
GENERAL INFORMATION (Continued)

²Check glow plug operation.
²Replace drive belt.
²Check engine smoke.
²Replace engine coolant.
35 000 KM
²Change engine oil.
²Change engine oil filter.
²Change MTX Fluid
40 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
²Diesel engines onlyÐReplace fuel filter/water
separator element.
45 000 KM
²Change engine oil.
²Change engine oil filter.
50 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
55 000 KM
²Change engine oil.
²Change engine oil filter.
60 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
²Diesel engines onlyÐReplace fuel filter/water
separator element.
65 000 KM
²Change engine oil.
²Change engine oil filter.
70 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
²Change MTX fluid
75 000 KM
²Change engine oil.
²Change engine oil filter.
80 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check glow plug operation.
²Replace drive belt.
²Check engine smoke.
²Replace engine coolant.
85 000 KM
²Change engine oil.
²Change engine oil filter.
90 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
95 000 KM
²Change engine oil.
²Change engine oil filter.
100 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
²Diesel engines onlyÐReplace fuel filter/water
separator element.
²Change MTX fluid
EVERY 5 000 KM AFTER 100 000 KM
²Change engine oil.
²Change engine oil filter.
EVERY 10 000 KM AFTER 100 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
²Check drive belt tension.
²Check glow plug operation.
EVERY 20 000 KM AFTER 100 000 KM
²Diesel engines onlyÐReplace fuel filter/water
separator element.
EVERY 35 000 KM AFTER 100 000 KM
²Change MTX fluid
0 - 4 LUBRICATION AND MAINTENANCENS/GS
GENERAL INFORMATION (Continued)

JUMP STARTING, HOISTING AND TOWING
INDEX
page
SERVICE PROCEDURES
TOWING RECOMMENDATIONS............. 5
SERVICE PROCEDURES
TOWING RECOMMENDATIONS
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACH-
MENT DEVICES TO CONTACT THE FUEL TANK OR
LINES, FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER, OR BUMPER ENERGY ABSORBER
UNITS.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not attach towing device to front or rear sus-
pension components.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects
from a damaged vehicle before towing.
Refer to state and local rules and regulations
before towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use of a flat bed towing device or wheel lift (Fig. 1) is
recommended. When using a wheel lift towing device,
be sure the disabled vehicle has at least 100 mm (4
in.) ground clearance. If minimum ground clearance
cannot be reached, use a towing dolly. If a flat bed
device is used, the approach angle should not exceed
15 degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels
removed, install lug nuts to retain brake drums or
rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the lifted end of
the vehicle and lower the vehicle closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²4-speed electronic automatic transaxle vehicles
can be flat towed at speeds not to exceed 72 km/h (44
mph) for not more than 160 km (100 miles). The
steering column must be unlocked and gear selector
in neutral.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
Fig. 1 Recommended Towing Devices
NS/GSLUBRICATION AND MAINTENANCE 0 - 5

SERVICE PROCEDURES
MASTER CYLINDER FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Master cylinder reservoirs are marked with the
words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder (Fig. 26).
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.When filling master
cylinder fluid reservoir do not fill the filler
neck of the fluid reservoir (Fig. 26) with brake
fluid.
Use only Mopartbrake fluid or an equivalent from
a sealed container. Brake fluid must conform to DOT
3, specifications.
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid ect.
BLEEDING BASE BRAKE HYDRAULIC SYSTEM
NOTE: This bleeding procedure is only for the vehi-
cle's base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, refer to the
ITT Teves Mark 20 Antilock Brake System bleeding
procedure in the antilock brakes section of this ser-
vice manual.
PRESSURE BLEEDING PROCEDURE
CAUTION: Before removing the master cylinder
cover, throughly clean the cover and master cylin-
der fluid reservoir to prevent dirt and other foreign
matter from dropping into the master cylinder fluid
reservoir.
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
CAUTION: When pressure bleeding the brakes
hydraulic system the fluid reservoir filler neck must
be removed from the master cylinder fluid reservoir.
Failure to remove the filler neck from the fluid res-
ervoir, may result in the filler neck separating from
the fluid reservoir when the hydraulic system is
pressurized.
Follow pressure bleeder manufacturer's instruc-
tions, for use of pressure bleeding equipment.
When bleeding the brake system, some air may be
trapped in the brake lines or valves far upstream, as
much as ten feet from the bleeder screw (Fig. 27).
Therefore, it is essential to have a fast flow of a large
volume of brake fluid when bleeding the brakes to
ensure all the air gets out.
(1) Remove the filler neck from the master cylin-
der fluid reservoir.
(2) Install the Adapter Master Cylinder Pressure
Bleed Cap, Special Tool 6921 on the fluid reservoir of
the master cylinder (Fig. 28). Attach the fluid hose
from the pressure bleeder to the fitting on Special
Tool 6921.
(3) Attach a clear plastic hose to the bleeder screw
at one wheel and feed the hose into a clear jar con-
taining fresh brake fluid.
Fig. 26 Master Cylinder Fluid Level Marks
Fig. 27 Trapped Air In Brake Fluid Line
5 - 20 BRAKESNS

REAR DRUM BRAKE WHEEL CYLINDER
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
BRAKE HOSE AND BRAKE LINES INSPECTION
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme-
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation
can cause twisting, resulting in wheel, tire, or chassis
interference.
The steel brake tubing should be inspected period-
ically for evidence of physical damage or contact with
moving or hot components.
The flexible brake tube sections used on this vehi-
cle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit
connections and the chassis brake tubes between the
hydraulic control unit and the proportioning valve
must also be inspected. This flexible tubing must be
inspected for kinks, fraying and its contact with
other components of the vehicle or contact with the
body of the vehicle.
REAR WHEEL HUB AND BEARING ASSEMBLY
The rear hub and bearing assembly is designed for
the life of the vehicle and should require no mainte-
nance. The following procedure may be used for eval-
uation of bearing condition.
With wheel and brake drum removed, rotate
flanged outer ring of hub. Excessive roughness, lat-
eral play or resistance to rotation may indicate dirt
intrusion or bearing failure. If the rear wheel bear-
ings exhibit these conditions during inspection, the
hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive
grease loss may also require bearing replacement.
Moderate grease loss from bearing is considered nor-
mal and should not require replacement of the hub
and bearing assembly.
ADJUSTMENTS
STOP LAMP SWITCH
(1) Remove stop lamp switch from its bracket by
rotating it approximately 30É in a counter-clockwise
direction.
(2) Disconnect wiring harness connector from stop
lamp switch.
(3) Hold stop lamp switch firmly in one hand.
Then using other hand, pull outward on the plunger
of the stop lamp switch until it has ratcheted out to
its fully extended position.
(4) Install the stop lamp switch into the bracket
using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp
switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting
bracket. When switch is fully installed in the square
hole of the bracket, rotate switch clockwise approxi-
mately 30É to lock the switch into the bracket.
CAUTION: Do not use excessive force when pulling
back on brake pedal to adjust the stop lamp switch.
If too much force is used, damage to the vacuum
booster, stop lamp switch or striker (Fig. 195) can
result.
(5) Connect the wiring harness connector to the
stop lamp switch.
(6) Gently pull back on brake pedal until the pedal
stops moving. This will cause the switch plunger
(Fig. 195) to ratchet backward to the correct position.
Fig. 195 Stop Light Switch Location In Vehicle
5 - 78 BRAKESNS
CLEANING AND INSPECTION (Continued)

(13) Lower the vehicle to the ground.Be sure
that the suspension is supporting the full
weight of the vehicle.
(14) Tighten the spring to front hanger pivot bolts
to a torque of 156 N´m (115 ft. lbs.).
(15) Tighten the shock absorber mounting bolts to
a torque of 101 N´m (75 ft. lbs.).
(16) Tighten the track bar mounting bolt to a
torque of 95 N´m (70 ft. lbs.).
(17) Road test vehicle to ensure that the prema-
ture rear wheel lockup condition has been corrected.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an equivalent from a
tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
Brake System Component Specifications
5 - 82 BRAKESNS
ADJUSTMENTS (Continued)

DESCRIPTION AND OPERATION
CLUTCH RELEASE SYSTEM
CLUTCH CABLE Ð LHD
The manual transaxle clutch release system has a
unique self-adjusting mechanism to compensate for
clutch disc wear (Fig. 7). This adjuster mechanism is
located within the clutch cable assembly. The preload
spring maintains tension on the cable. This tension
keeps the clutch release bearing continuously loaded
against the fingers of the clutch cover assembly.
HYDRAULIC CLUTCH Ð RHD
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage to disengage and engage the modular clutch
assembly.
The modular clutch assembly contains the cover,
diaphragm spring, pressure plate, disc and flywheel
in one unit. The modular clutch also uses a drive
plate and is bolted to and driven by the drive plate.
The clutch linkage uses hydraulic pressure to oper-
ate the clutch. The clutch master cylinder push rod is
connected to the clutch pedal and the slave cylinder
push rod is connected to the release lever in the
clutch housing.
Depressing the clutch pedal develops fluid pressure
in the clutch master cylinder. This pressure is trans-
mitted to the slave cylinder through a connecting
line. In turn, the slave cylinder operates the clutch
release lever.
The clutch release bearing is mounted on the
transmission front bearing retainer. The bearing is
attached to the release lever, which moves the bear-
ing into contact with the clutch cover diaphragm
spring.Slave cylinder force causes the release lever to
move the release bearing into contact with the dia-
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward
on the fulcrums. This action moves the pressure
plate rearward relieving clamp force on the disc. The
clutch disc is disengaged and not driven at this point.
The process of clutch engagement is simply the
reverse of what occurs during disengagement. Releas-
ing pedal pressure removes clutch linkage pressure.
The release bearing moves away from the diaphragm
spring which allows the pressure plate to exert
clamping force on the clutch disc.
CLUTCH PEDAL POSITION SWITCH
The clutch pedal position switch functions as a
safety interlock device. It prevents possible engine
cranking with the clutch engaged.
The clutch pedal position switch is wired in series
between the starter relay coil and the ignition
switch.
The clutch pedal position switch is mounted to a
bracket located behind the clutch pedal. The switch
is held in place by four plastic wing tabs.
The clutch pedal position switch IS NOT adjust-
able. The pedal blade contacts the switch in the down
position (Fig. 8).
DIAGNOSIS AND TESTING
CLUTCH PEDAL POSITION SWITCH
CLUTCH PEDAL POSITION
SWITCH±ELECTRICAL TEST
Disconnect clutch pedal position switch harness
from instrument panel wiring harness. Using an
ohmmeter, check for continuity between the two ter-
minals in the connector on the switch harness. There
should be no continuity between the terminals when
Fig. 7 Clutch Cable Ð LHD
Fig. 8 Clutch Pedal Position Switch and
Components Ð LHD Shown
6 - 4 CLUTCHNS/GS

CLUTCH DIAGNOSIS
Problem diagnosis will generally require a road
test to determine the type of fault. Component
inspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges andobserve clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSIS±CLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or transaxle
input shaft sealCorrect leak and replace clutch assembly
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to suspension
or driveline componentFurther diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems Check EFI and ignition systems
PARTIAL ENGAGEMENT
OF CLUTCH DISCClutch cover, spring, or release fingers
bent, distorted (rough handling, improper
assembly)Replace clutch assembly
Clutch disc damaged or distorted Replace clutch assembly
Clutch misalignment Check alignment and runout of flywheel,
disc, or cover. Check clutch housing to
engine dowels and dowel holes for
damage. Correct as necessary.
SERVICE DIAGNOSIS±CLUTCH SLIPS
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN
OUTNormal wear. Replace clutch assembly.
Driver frequently rides (slips) clutch,
results in rapid wear overheating.Replace clutch assembly
Insufficient clutch cover diaphragm
spring tensionReplace clutch assembly
CLUTCH DISC FACING
CONTAMINATED WITH
OIL OR GREASELeak at rear main oil seal or transaxle
input shaft sealReplace leaking seals. Replace clutch
assembly.
Road splash, water entering housing Seal housing. Inspect clutch assembly.
CLUTCH IS RUNNING
PARTIALLY
DISENGAGEDRelease bearing sticking or binding,
does not return to normal running
position.Verify that bearing is actually binding.
Then, replace bearing and transmission
front bearing retainer if sleeve surface is
damaged.
Cable self-adjuster mechanism sticking
or binding causing high preload (LHD
Applications only)Verify that self-adjuster is free to move
(LHD Applications only)
CLUTCH DISC FACINGS
HAVE FRACTURED INTO
SMALL PIECESDriver performs a 5-1 downshift at
vehicle speed in excess of 60 miles per
hourAlert driver to problem cause. Replace
clutch assembly.
Excessive heat from slippage Replace clutch assembly
6 - 6 CLUTCHNS/GS
DIAGNOSIS AND TESTING (Continued)