1996 CHRYSLER VOYAGER engine

boxes behind the front wheels and forward of the
rear wheels inboard of the rocker panel weld seam.
TOWINGÐFRONT WHEEL LIFT
Chrysler Corporation recommends that a vehicle be
towed with the front end lifted, whenever possible. A
90 cm (36 in.) length of 4x4 wood beam can be placed
between the wheel lift device and the bottom of the
fascia to prevent damage to vehicle during the lifting
operation. The beam can removed after lifting the
front of the vehicle.
TOWINGÐREAR WHEEL LIFT
If a vehicle cannot be towed with the front wheels
lifted, the rear wheels can be lifted provided the fol-
lowing guide lines are observed.
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
²On AWD vehicles, all four wheels must be free to
rotate. Use towing dollies at unlifted end of vehicle.
²Unlock steering column and secure steering
wheel in straight ahead position with a clamp device
designed for towing.
²3-speed automatic transaxle vehicles can be flat
towed at speeds not to exceed 40 km/h (25 mph) for
not more than 25 km (15 miles). The steering column
must be unlocked and gear selector in neutral.
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.
HOISTING RECOMMENDATIONS
Refer to Owner's Manual provided with vehicle for
proper emergency jacking procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN THE ENGINE OR REAR SUSPENSION
IS REMOVED FROM A VEHICLE, THE CENTER OF
GRAVITY IS ALTERED MAKING SOME HOISTING
CONDITIONS UNSTABLE. PROPERLY SUPPORT ORSECURE VEHICLE TO HOISTING DEVICE WHEN
THESE CONDITIONS EXIST.
CAUTION: Do not position hoisting device on sus-
pension components or front crossmember, dam-
age to vehicle can result.
TO HOIST OR JACK VEHICLE SEE(Fig. 3).
Vehicles with factory installed ground effects are
equipped with front and rear hoisting pads. These
pads are stamped, ªHoist Pointº.
Fig. 3 HOISTING AND JACKING POINTS
NSLUBRICATION AND MAINTENANCE 0 - 9
SERVICE PROCEDURES (Continued)

LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION.................. 1
JUMP STARTING, HOISTING AND TOWING . . . 5MAINTENANCE SCHEDULES............... 2
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
ENGINE OIL Ð GASOLINE ENGINES........ 1
ENGINE OILÐDIESEL ENGINES............ 1FLUID CAPACITIES...................... 1
MANUAL TRANSMISSION FLUID
(A-558 and A-598 Models)................ 1
GENERAL INFORMATION
ENGINE OIL Ð GASOLINE ENGINES
Use only oils conforming to API (American Petro-
leum Institute) Quality SJ and Energy Conserving II,
or SH and Energy Conserving II, or ACEA A1±96.
SAE VISCOSITY GRADE
To assure of properly formulated engine oils, it is
recommended that SAE Grade 5W-30 engine oils that
meet Chrysler material standard MS-6395, be used.
SAE Grade 10W-30 oils are also acceptable when the
temperatures do not fall below 0ÉC. In areas where
these grades are not generally available, higher SAE
grades may be used.
Lubricants which have both an SAE grade number
and the proper API service classification shown on
the container should be used.
ENGINE OILÐDIESEL ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationSG/CDorCCMC PD2.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is recom-
mended that SAE Grade 15W-40 engine oils that meet
Chrysler material standard MS-6395, be used. European
Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-30 or 10W-30 grade number
are preferred when minimum temperatures consis-
tently fall below -12ÉC.
MANUAL TRANSMISSION FLUID (A-558 and A-598
Models)
Use only SAE 10W-40 engine oils carrying the
European CCMC-G5 classification to fill the A-598
5±speed manual transmission.
FLUID CAPACITIES
Fuel Tank.............................76L
2.0L Gasoline Engine Oil with Filter........4.3L
2.5L VM Diesel Engine Oil With Filter......6.5L
2.0L Gasoline Engine Cooling System*.......6.0L
2.5L VM Diesel Engine Cooling System*....10.0 L
TransmissionÐ5-Speed Manual............2.2L
* Includes heater and coolant recovery tank filled
to Max level. Add 2.76L if equipped with Rear
Heater.
NS/GSLUBRICATION AND MAINTENANCE 0 - 1

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULE............... 2
MAINTENANCE SCHEDULEÐ
DIESEL ENGINE....................... 2SCHEDULEÐA (DIESEL).................. 2
SCHEDULEÐB (DIESEL).................. 3
UNSCHEDULED INSPECTION.............. 2
GENERAL INFORMATION
MAINTENANCE SCHEDULE
Refer to the 1998 GS Service Manual for Gasoline
Engine and non-engine related Maintenance Sched-
ules.
MAINTENANCE SCHEDULEÐDIESEL ENGINE
The following are engine related Maintenance
items which are unique to Diesel engine-equipped
vehicles. Refer to the 1998 GS Service Manual for
Gasoline Engine and non-engine related Maintenance
Schedules.
The service intervals are based on odometer read-
ings in kilometers. There are two maintenance sched-
ules that show proper service intervals. Use the
schedule that best describes the conditions the vehi-
cle is operated under.Schedule-Alists all the sched-
uled maintenance to be performed under normal
operating conditions.Schedule-Bis the schedule for
vehicles that are operated under one or more of the
following conditions:
²Day and night temperatures are below freezing.
²Stop and go driving.
²Long periods of engine idling.
²Driving in dusty conditions.
²Short trips of less than 5 miles.
²Operation at sustained high speeds during hot
weather above 32ÉC (90ÉF).
²Taxi, police or delivery service.
²Trailer towing.
UNSCHEDULED INSPECTION
At Each Stop for Fuel
²Check engine oil level, add as required.
²Check windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect battery and clean and tighten terminals
as required.²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator
for proper fit.
At Each Oil Change
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on ScheduleÐA (7,500 miles) or every other
interval shown on ScheduleÐ B (6,000 miles).
²Check the coolant level, hoses, and clamps.
²If your mileage is less than 7,500 miles (12 000
km) yearly, replace the engine oil filter at each oil
change.
²Replace engine oil filter.
SCHEDULEÐA (DIESEL)
1 000 KM
²Change engine oil.
²Change engine oil filter.
²Check all fluid levels.
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.
10 000 KM
²Change engine oil.
²Change engine oil filter.
20 000 KM
²Change engine oil.
²Change engine oil filter.
²Replace air filter element.
0 - 2 LUBRICATION AND MAINTENANCENS/GS

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

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or Grinding On
Turns1. Defective wheel bearing 1. Replace wheel bearing
2. Engine mount grounding 2. Check for motor mount hitting
frame rail and reposition engine as
required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
6. Worn tires 6. Replace tires
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Front End Clunk Or Snap On Turns 1. Loose lug nuts 1. Verify wheel lug nut torque
2. Worn or broken C/V joint 2. Replace C/V joint
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body
attachment7. Tighten strut attachment to
specified torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With Vehicle
Going Straight At A Constant Speed1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
4. Worn or defective transaxle gears
or bearings4. Replace transaxle gears or
bearings
Front End Growl Or Grinding With
Vehicle Going Straight At A
Constant Speed1. Engine mount grounding 1. Reposition engine as required
2. Worn or broken C/V joint 2. Replace C/V joint
Front End Whine When
Accelerating Or Decelerating1. Worn or defective transaxle gears
or bearings1. Replace transaxle gears or
bearings
Front End Clunk When Accelerating
Or Decelerating1. Worn or broken engine mount 1. Replace engine mount
2. Worn or defective transaxle gears
or bearings2. Replace transaxle gears or
bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
4. Worn or broken C/V joint 4. Replace C/V joint
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
NSSUSPENSION 2 - 3

BASE BRAKE SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
CHASSIS TUBES AND HOSES.............. 7
FRONT DISC BRAKE SYSTEM.............. 4
HUB/BEARING REAR WHEEL............... 9
MASTER CYLINDER...................... 7
PARKING BRAKE SYSTEM OPERATION....... 5
POWER BRAKE VACUUM BOOSTER
OPERATION........................... 8
PROPORTIONING VALVES................. 5
REAR DISC BRAKES...................... 5
REAR DRUM BRAKES..................... 5
RED BRAKE WARNING LAMP OPERATION..... 8
STOP LAMP SWITCH...................... 9
DIAGNOSIS AND TESTING
ADJUSTER REAR DRUM BRAKE
(AUTOMATIC)......................... 14
BRAKE FLUID CONTAMINATION............ 19
BRAKE ROTOR......................... 14
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE.... 9
BRAKE SYSTEM DIAGNOSIS CHARTS....... 10
PROPORTIONING VALVES................ 16
RED BRAKE WARNING LAMP TEST......... 19
STOP LAMP SWITCH TEST PROCEDURE..... 19
TRACTION CONTROL LAMP TEST.......... 19
SERVICE PROCEDURES
BLEEDING BASE BRAKE
HYDRAULIC SYSTEM................... 20
BRAKE DRUM MACHINING................ 24
BRAKE TUBE REPAIR PROCEDURE......... 24
MASTER CYLINDER BLEEDING
PROCEDURE......................... 22
MASTER CYLINDER FLUID LEVEL CHECK.... 20
PARK BRAKE AUTO ADJUSTER
MECHANISM RELEASE................. 26
ROTOR MACHINING (FRONT/REAR)......... 22
REMOVAL AND INSTALLATION
BRAKE SUPPORT PLATE (REAR DRUM
BRAKES)............................ 37
FRONT DISC BRAKE CALIPER............. 27
FRONT DISC BRAKE PADS................ 30
FRONT PARK BRAKE CABLE.............. 65
HUB/BEARING.......................... 40
HYDRAULIC BRAKE TUBES AND HOSES..... 58
INTERMEDIATE PARK BRAKE CABLE....... 66
JUNCTION BLOCK....................... 55
LEFT REAR PARK BRAKE CABLE........... 67
MASTER CYLINDER..................... 44
PARK BRAKE PEDAL MECHANISM.......... 58PARK BRAKE SHOES (WITH REAR DISC
BRAKES)............................ 60
PROPORTIONING VALVE (W/ABS BRAKES) . . . 56
PROPORTIONING VALVE
(W/O ABS BRAKES).................... 57
REAR BRAKE DRUM..................... 33
REAR BRAKE WHEEL CYLINDER........... 39
REAR DISC BRAKE CALIPER.............. 28
REAR DISC BRAKE SHOES................ 31
REAR DRUM BRAKE SHOES............... 34
RIGHT REAR PARK BRAKE CABLE......... 66
STOP LAMP SWITCH..................... 69
VACUUM BOOSTER 2.4 LITER ENGINE...... 47
VACUUM BOOSTER 3.0 LITER ENGINE...... 49
VACUUM BOOSTER 3.3/3.8 LITER ENGINE.... 52
WHEEL AND TIRE INSTALLATION........... 27
DISASSEMBLY AND ASSEMBLY
FRONT DISC BRAKE CALIPER............. 71
MASTER CYLINDER BRAKE FLUID LEVEL
SWITCH............................. 71
MASTER CYLINDER FLUID RESERVOIR
FILL TUBE............................ 71
MASTER CYLINDER FLUID RESERVOIR...... 70
MASTER CYLINDER TO POWER BRAKE
BOOSTER VACUUM SEAL............... 69
WHEEL CYLINDER REAR DRUM BRAKE...... 76
CLEANING AND INSPECTION
BRAKE HOSE AND BRAKE LINES
INSPECTION.......................... 78
FRONT DISC BRAKE PAD LINING
INSPECTION.......................... 76
REAR DISC BRAKES..................... 76
REAR DRUM BRAKE SHOE LINING
INSPECTION.......................... 77
REAR DRUM BRAKE WHEEL CYLINDER...... 78
REAR WHEEL HUB AND BEARING
ASSEMBLY........................... 78
ADJUSTMENTS
PARK BRAKE CABLE ADJUSTMENT......... 81
PARK BRAKE SHOES (WITH REAR DISC
BRAKES)............................ 79
PROPORTIONING VALVE
(HEIGHT SENSING).................... 81
REAR DRUM BRAKE SHOE ADJUSTMENT.... 79
STOP LAMP SWITCH..................... 78
SPECIFICATIONS
BRAKE ACTUATION SYSTEM.............. 83
BRAKE FASTENER TORQUE
SPECIFICATIONS...................... 83
NSBRAKES 5 - 3