1996 CHRYSLER VOYAGER automatic transmission

DIGITS 16, 17, AND 18
Vehicle Shell Car Line
²GSYH = Voyager/Grand Voyager SE FWD
²GSYP = Voyager/Grand Voyager LE FWD
²GSYS = Voyager LX FWD
²GSCP = Voyager/Grand Voyager LE AWD
²GSCS = Voyager LX AWD
DIGIT 19
Price Class
²H = High Line
²P = Premium
²S = Special/SportDIGITS 20 AND 21
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATEÐLINE 2
DIGITS 1,2, AND 3
Paint Procedure
DIGIT 4
Open Space
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = United States or Austria
2 = Canada
2 Make C = Chrysler
D = Dodge
3 Vehicle Type 4 = Multipurpose Pass. Veh.
4 Gross Vehicle Weight Rating G = 2268-2721 kg (5001-6000 lbs)
5 Car Line C = Voyager/Grand Voyager AWD
Y = Voyager/Grand Voyager FWD
6 Series 4 = Voyager/Grand Voyager SE FWD
5 = Voyager/Grand Voyager LE FWD/AWD
6 = Voyager LX FWD/AWD
N = 5-Speed Manual Transmission
B = 4-Speed Automatic Transmission
7 Body Style 2 = Short Wheelbase 4-Door
3 = Short Wheelbase 3-Door
4 = Long Wheelbase Premium 4-Door
5 = Long Wheelbase Highline 4-door
7 = Short Wheelbase Commercial Van
8 Engine B = 2.4 L 4cyl. MPI 16-Valve DOHC
C = 2.0L 4cyl. MPI 16-Valve SOHC
M = 2.5L 4cyl Turbo Diesel (Intercooler)
R = 3.3 L 6 cyl. gas MPI
L = 3.8 L 6 cyl. gas MPI
9 Check Digit See explanation in this section.
10 Model Year W = 1998
11 Assembly Plant B = St. Louis South, U.S.A.
R = Windsor, Canada
U = Graz, Austria
12 Build Sequence 6 Digit number assigned by assembly plant
2 INTRODUCTIONNS/GS
GENERAL INFORMATION (Continued)

MAINTENANCE SCHEDULES
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 3
SCHEDULE ± A.......................... 3SCHEDULE ± B.......................... 4
UNSCHEDULED INSPECTION............... 3
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
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 Schedule ± A (7,500 miles) or every other
interval shown on Schedule ± 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 on 2.4L engines.
SCHEDULE ± A
7,500 Miles (12 000 km) or at 6 months
²Change engine oil.
15,000 Miles (24 000 km) or at 12 months
²Change engine oil.
²Replace engine oil filter.
22,500 Miles (36 000 km) or at 18 months
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km) or at 24 months
²Change engine oil.
²Change automatic transmission fluid.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect tie rod ends and boot seals.
37,500 Miles (60 000 km) or at 30 months
²Change engine oil.
45,000 Miles (72 000 km) or at 36 months
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
²Flush and replace engine coolant at 36 months,
regardless of mileage.
NSLUBRICATION AND MAINTENANCE 0 - 3

52,500 Miles (84 000 km) or at 42 months
²Change engine oil.
²Flush and replace engine coolant if not done at
36 months.
60,000 Miles (96 000 km) or at 48 months
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace, if necessary.
*
²Inspect serpentine drive belt, replace if neces-
sary.
²Inspect tie rod ends and boot seals.
67,500 Miles (108 000 km) or at 54 months
²Change engine oil.
²Inspect brake linings.
75,000 Miles (120 000 km) or at 60 months
²Change engine oil.
²Replace engine oil filter.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 Miles (132 000 km) or at 66 months
²Change engine oil.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 Miles (144 000 km) or at 72 months
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace, if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
97,500 Miles (156 000 km) or at 78 months
²Change engine oil.
100,000 Miles (160,000 km)
²Replace spark plugs on 3.3L and 3.8L
engines.
²Replace ignition cables on 3.3L and 3.8L
engines.
105,000 Miles (168 000 km) or at 84 months
²Change engine oil.
²Replace engine oil filter.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
112,500 Miles (180 000 km) or at 90 months
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
120,000 Miles (192 000 km) or at 96 months
²Change engine oil.
²Replace engine oil filter.
²Replace automatic transmission fluid.
²Replace engine air cleaner element.
²Check and replace PCV valve, if necessary.
*
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
SCHEDULE ± B
3,000 Miles (5 000 km)
²Change engine oil.
6,000 Miles (10 000 km)
²Change engine oil.
²Replace engine oil filter.
9,000 Miles (14 000 km)
²Change engine oil.
²Inspect brake linings.
12,000 Miles (19 000 km)
²Change engine oil.
²Replace engine oil filter.
15,000 Miles (24 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
0 - 4 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)

²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD powertransfer fluid unit.
18,000 Miles (29 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
21,000 Miles (34 000 km)
²Change engine oil.
²Check AWD overrunning clutch and rear carrier
fluid.
24,000 Miles (38 000 km)
²Change engine oil.
²Replace engine oil filter.
27,000 Miles (43 000 km)
²Change engine oil.
²Inspect brake linings.
30,000 Miles (48 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
33,000 Miles (53 000 km)
²Change engine oil.
36,000 Miles (58 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
39,000 Miles (62 000 km)
²Change engine oil.
42,000 Miles (67 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
45,000 Miles (72 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Inspect brake linings.
²Change AWD power transfer unit fluid.
48,000 Miles (77 000 km)
²Change engine oil.
²Replace engine oil filter.
51,000 Miles (82 000 km)
²Change engine oil.
²Flush and replace engine coolant.
54,000 Miles (86 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
57,000 Miles (91 000 km)
²Change engine oil.
60,000 Miles (96 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve, replace if necessary. *
²Inspect serpentine drive belt, replace if neces-
sary.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
63,000 Miles (101 000 km)
²Change engine oil.
²Change AWD overrunning clutch and rear car-
rier fluid.
²Inspect brake linings.
66,000 Miles (106 000 km)
²Change engine oil.
²Replace engine oil filter.
69,000 Miles (110 000 km)
²Change engine oil.
72,000 Miles (115 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
75,000 Miles (120 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
NSLUBRICATION AND MAINTENANCE 0 - 5
GENERAL INFORMATION (Continued)

²Replace spark plugs.
²Replace ignition cables.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transaxle fluid and
replace filter. Adjust band, if so equipped. (See note)
²Change AWD power transfer unit fluid.
78,000 Miles (125 000 km)
²Change engine oil.
²Replace engine oil filter.
81,000 Miles (130 000 km)
²Change engine oil.
²Inspect brake linings.
²Flush and replace engine coolant.
84,000 Miles (134 000 km)
²Change engine oil.
²Replace engine oil filter.
²Change AWD overrunning clutch and rear car-
rier fluid.
87,000 Miles (139 000 km)
²Change engine oil.
90,000 Miles (144 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Check PCV valve and replace if necessary.
Not required if previously changed. *
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped. (See
note)
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
²Inspect brake linings.
93,000 Miles (149 000 km)
²Change engine oil.
96,000 Miles (154 000 km)
²Change engine oil.
²Replace engine oil filter.
99,000 Miles (158 000 km)
²Change engine oil.
²Inspect brake linings.
102,000 Miles (163 000 km)
²Change engine oil.
²Replace engine oil filter.
105,000 Miles (168 000 km)
²Change engine oil.
²Inspect air cleaner element. Replace as
necessary.
²Inspect serpentine drive belt, replace if neces-
sary. This maintenance is not required if belt was
previously replaced.
²Drain and refill automatic transmission fluid
and filter. Adjust bands, if so equipped. (See note)
²Change AWD power transfer unit fluid.
²Change AWD overrunning clutch and rear car-
rier fluid.
108,000 Miles (173 000 km)
²Change engine oil.
²Replace engine oil filter.
²Inspect brake linings.
111,000 Miles (178 000 km)
²Change engine oil.
²Flush and replace engine coolant.
114,000 Miles (182 000 km)
²Change engine oil.
²Replace engine oil filter.
117,000 Miles (187 000 km)
²Change engine oil.
²Inspect brake linings.
120,000 Miles (192 000 km)
²Change engine oil.
²Replace engine oil filter.
²Replace air cleaner element.
²Inspect PCV valve. Replace as necessary. *
²Inspect serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Drain and refill automatic transmission fluid
and replace filter. Adjust bands, if so equipped.
²Change AWD power transfer unit fluid.
²Inspect tie rod ends and boot seals.
* This maintenance is recommended by Chrysler to
the owner but is not required to maintain the war-
ranty on the PCV valve.
** If California vehicle, this maintenance is recom-
mended by Chrysler to the owner but is not required
to maintain the warranty of the timing belt.
NOTE: Operating vehicle more than 50% in heavy
traffic during hot weather, above 90ÉF (32ÉC), using
vehicle for police, taxi, limousine type operation or
trailer towing require the more frequent transaxle
service noted in Schedule ± B. Perform these ser-
vices if vehicle is usually operated under these con-
ditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 6 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)

JUMP STARTING, HOISTING AND TOWING
INDEX
page page
SERVICE PROCEDURES
HOISTING RECOMMENDATIONS............ 9JUMP STARTING PROCEDURE.............. 7
TOWING RECOMMENDATIONS.............. 8
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Yellow or bright color test indicator, if equipped.
²Low battery fluid level.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, placethe automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 1).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Allow battery in disabled vehicle to charge to
at least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec-
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
Fig. 1 Jumper Cable Clamp Connections
NSLUBRICATION AND MAINTENANCE 0 - 7

COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELTS................ 1
AUTOMATIC TRANSMISSION OIL COOLERÐ
2.4L................................. 3
COOLANT RECOVERY SYSTEM (CRS)....... 3
COOLANT.............................. 3
COOLING SYSTEM....................... 2
ENGINE BLOCK HEATER.................. 5
ENGINE THERMOSTAT.................... 3
RADIATOR PRESSURE CAP................ 4
RADIATOR............................. 3
WATER PUMPS......................... 3
DESCRIPTION AND OPERATION
COOLANT PERFORMANCE................. 6
RADIATOR HOSES AND CLAMPS........... 6
WATER PIPESÐ3.0L ENGINE.............. 6
WATER PUMPÐ3.3/3.8L ENGINES.......... 7
WATER PUMPÐ2.4L ENGINE.............. 6
WATER PUMPÐ3.0L ENGINE.............. 6
DIAGNOSIS AND TESTING
ACCESSORY DRIVE BELT.................. 7
COOLING SYSTEM DIAGNOSIS............. 8
DEAERATION.......................... 16
ELECTRIC FAN MOTOR TEST.............. 14
LOW COOLANT LEVEL AERATION.......... 15
PRESSURE TESTING RADIATOR CAP....... 15
RADIATOR CAP TO FILLER NECK SEAL
PRESSURE RELIEF CHECK.............. 15
RADIATOR COOLANT FLOW TEST.......... 14
RADIATOR FAN CONTROL................ 14
TEMPERATURE GAUGE INDICATION........ 16
TESTING COOLING SYSTEM FOR LEAKS.... 14
SERVICE PROCEDURES
COOLANT LEVEL CHECKÐROUTINE........ 16
COOLANT LEVEL SERVICE................ 16COOLANTÐADDING ADDITIONAL.......... 16
COOLING SYSTEMÐDRAINING............ 16
COOLING SYSTEMÐREFILLING........... 16
REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELTSÐ2.4L.......... 23
ACCESSORY DRIVE BELTSÐ3.0L.......... 24
ACCESSORY DRIVE BELTÐ3.3/3.8L........ 24
ENGINE BLOCK HEATER................. 23
FAN MODULE.......................... 22
RADIATOR DRAINCOCK.................. 21
RADIATOR............................ 21
THERMOSTATÐ2.4L ENGINE............. 19
THERMOSTATÐ3.0L ENGINE............. 20
THERMOSTATÐ3.3/3.8L ENGINES......... 20
WATER PUMP INLET TUBEÐ2.4L ENGINE . . . 17
WATER PUMPÐ3.3/3.8L ENGINES......... 19
WATER PUMPÐ2.4L ENGINE............ 17
WATER PUMPÐ3.0L ENGINE............. 18
CLEANING AND INSPECTION
ACCESSORY DRIVE BELT................. 25
CHEMICAL CLEANING................... 25
COOLING SYSTEM CLEANING............. 25
RADIATOR PRESSURE CAP............... 25
REVERSE FLUSHING THE ENGINE......... 25
REVERSE FLUSHING THE RADIATOR....... 25
WATER PUMP......................... 24
ADJUSTMENTS
BELT TENSION CHART................... 26
BELT TENSION GAUGE METHOD........... 26
PROPER BELT TENSION................. 25
SPECIFICATIONS
COOLING SYSTEM CAPACITY............. 26
TORQUE CHART........................ 26
SPECIAL TOOLS
COOLING............................. 26
GENERAL INFORMATION
ACCESSORY DRIVE BELTS
The accessory drive system utilizes two different
style of drive belts. The conventional V-belt and the
Poly-V belt are used to drive the generator, air con-
ditioning compressor, power steering pump and waterpump. Satisfactory performance of these belts
depends on belt condition and proper belt tension.
Belt tensioning should be performed with the aid of a
Burroughs gauge Special Tool C-4162. Because of
space limitations in the engine compartment, the use
of the gauge may be restricted. Raise the vehicle on a
hoist and then remove the splash shield to gain
access to the drive belts.
NSCOOLING SYSTEM 7 - 1

COOLING SYSTEM
The cooling system has a radiator, coolant, electric fan
motor, shroud, pressure cap, thermostat, coolant reserve
system, transmission oil cooler, a water pump to circulate
the coolant, hoses, and clamps to complete the circuit.
²When Engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²
When Engine is warm: thermostat is open, cooling
system has bypass flow and coolant flow through radia-
tor.
Its primary purpose is to maintain engine temper-
ature in a range that will provide satisfactory engine
performance and emission levels under all expected
driving conditions. It also provides hot water (cool-
ant) for heater performance and cooling for automatic
transmission oil. It does this by transferring heat
from engine metal to coolant, moving this heated
coolant to the radiator, and then transferring this
heat to the ambient air.
Coolant flow circuits for 2.4L and 3.3/3.8L engines
are shown in (Fig. 1), and 3.0L engine coolant rout-
ing is shown in (Fig. 2)
Fig. 1 Cooling System Operation 2.4L and 3.3/3.8L Engines
Fig. 2 Cooling System Operation 3.0L Engine
7 - 2 COOLING SYSTEMNS
GENERAL INFORMATION (Continued)