1996 CHRYSLER VOYAGER battery

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension
5Brakes
6Clutch
7Cooling System
8ABattery
8BStarting System
8EInstrument Panel and Systems
8HVehicle Speed Control System
8KWiper and Washer Systems
8LLamps
8QVehicle Theft/Security Systems
8UChime Warning/Reminder System
8WWiring Diagrams
9Engine
13Frame and Bumpers
14Fuel SystemÐ2.5L Diesel Engine/2.0L Gas Engine
19Steering
21AÐ598 Manual Transaxle
23Body
24Heating and Air Conditioning
25Emission Control System

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

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

DISCONNECT CABLE CLAMPS AS FOLLOWS:
²Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
²When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive
terminal.
²Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.
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. 2) 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
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.
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.
NS vehicles can be tied to a flat bed device using
the reinforced loops located under the front and rear
bumpers on the drivers side of the vehicle. There are
also four reinforced elongated holes for T or R-hooks
located on the bottom of the front frame rail torque
Fig. 2 Recommended Towing Devices
0 - 8 LUBRICATION AND MAINTENANCENS
SERVICE PROCEDURES (Continued)

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

normal. This may indicate:(1)Abnormal loss of
brake fluid in the master cylinder fluid reservoir
resulting from a leak in the hydraulic system.(2)
Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level sensor closes to ground the
brake warning light circuit. This will turn on the red
brake warning light. At this time, master cylinder
fluid reservoir should be checked and filled to the full
mark with DOT 3 brake fluid.If brake fluid level
has dropped below the add line in the master
cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evi-
dence of a leak.
STOP LAMP SWITCH
The stop lamp switch controls operation of the
vehicles stop lamps. Also, if the vehicle is equippedwith speed control, the stop lamp switch will deacti-
vate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the
right and left tail, stop and turn signal lamp and
CHMSL lamp, by supplying battery current to these
lamps.
The stop lamp switch controls the lamp operation
by opening and closing the electrical circuit to the
stop lamps.
HUB/BEARING REAR WHEEL
The rear hub and bearing assembly used on this
vehicle is serviceable only as a complete assembly. No
attempt should be made to disassemble a rear hub
and bearing assembly in an effort to repair it.
The rear hub and bearing assembly is attached to
the rear axle using 4 mounting bolts that are remov-
able from the back of the rear hub/bearing.
DIAGNOSIS AND TESTING
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE
SYMPTOMCHART 1
MISC.
COND.CHART 2
WARNING
LIGHTCHART 3
POWER
BRAKESCHART 4
BRAKE
NOISECHART 5
WHEEL
BRAKES
Brake Warning Light On X NO NO
Excessive Pedal Travel 6 X NO O
Pedal Goes To The Floor 6 X
Stop Light On Without Brakes 3
All Brakes Drag 5
Rear Brakes Drag 2 NO NO
Grabby Brakes O X
Spongy Brake Pedal X NO
Premature Rear Brake Lockup 4 NO NO O
Excessive Pedal Effort 1 O
Rough Engine Idle NO O
Brake Chatter (Rough) NO NO X
Surge During Braking NO NO X
Noise During Braking NO NO X
Rattle Or Clunking Noise NO NO X
Pedal Pulsates During Braking NO NO X
Pull To Right Or Left NO NO X
No: Not A Possible Cause X: Most Likely Cause O: Possible Cause
NSBRAKES 5 - 9
DESCRIPTION AND OPERATION (Continued)

CAUTION: When installing the primary and second-
ary brake tubes on master cylinder, be sure brake
tubes do not contact any other components within
the vehicle and that there is slack in the flexible
sections of the tubes. This is required due to the
movement between the ABS hydraulic control mod-
ule (HCU) and the master cylinder, when the vehicle
is in motion.
(4) Connect the primary and secondary brake
tubes to master cylinder primary and secondary
ports (Fig. 99). Brake tubes must be held securely
when tightened to control orientation of flex section.
Then fully tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
(5) Install the vehicle wiring harness connector, on
the brake fluid level sensor in the master cylinder
brake fluid reservoir (Fig. 98).
(6) Install filler tube into the master cylinder fluid
reservoir (Fig. 97).
VACUUM BOOSTER 2.4 LITER ENGINE
REMOVE
CAUTION: Reserve vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from vacuum booster. This is nec-
essary to prevent the vacuum booster from sucking
in any contamination as the master cylinder is
removed. This can be done simply by pumping the
brake pedal, with the vehicle's engine not running,
until a firm feeling brake pedal is achieved.
(1) With engine not running, pump brake pedal
until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 104)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 105)
attaching the battery tray to the body.
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 106).
(9) Clean the area where the master cylinder
assembly attaches to the power brake booster. Useonly a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
(10) Remove clip attaching drain hose for wiper
module to brake tube at master cylinder. Remove
Fig. 104 Air Inlet Resonator
Fig. 105 Battery Tray Mounting Locations
Fig. 106 Fluid Level Sensor Electrical Connection
NSBRAKES 5 - 47
REMOVAL AND INSTALLATION (Continued)

(7) Install aNEWvacuum seal on mounting flange
of master cylinder (Fig. 110).
(8) Position master cylinder on studs of vacuum
booster aligning push rod on vacuum booster with
master cylinder piston.
(9) Install the 2 nuts (Fig. 107) mounting the mas-
ter cylinder to the vacuum booster. Tighten the
mounting nuts to a torque of 25 N´m (225 in. lbs.).
(10) Install the wiper module drain hose (Fig. 107)
on the wiper module. Install the tie strap attaching
the wiper module drain hose to the brake tube at the
master cylinder.Tie strap should be loosely tight-
ened so as not to collapse the wiper module
drain hose.
(11) Install the wiring harness connector on the
brake fluid level sensor in the master cylinder fluid
reservoir (Fig. 106).
(12) Install the battery tray in the vehicle. Install
the 2 bolts and the nut (Fig. 105) attaching the bat-
tery tray. Tighten the 2 bolts and the nut to a torque
of 14 N´m (125 in lbs.).(13) If vehicle is equipped with speed control,
install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attach-
ing bracket to battery tray.
(14) If vehicle is equipped with speed control,
install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto
the speed control servo and vacuum reservoir on bat-
tery tray.
(15) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing (Fig. 104). Securely tighten the hose clamp at the
air cleaner housing and throttle body.
(16) Install the battery and the battery thermal
guard.
(17) Install the battery cables on the battery.
(18) Check the operation of the stop lamp switch
and adjust if necessary.
VACUUM BOOSTER 3.0 LITER ENGINE
REMOVE
CAUTION: Stored vacuum in the vacuum booster
must be pumped down (removed) before removing
master cylinder from power brake booster. This is
necessary to prevent the power brake booster from
sucking in any contamination as the master cylin-
der is removed. This can be done simply by pump-
ing the brake pedal, with the vehicle's engine not
running, until a firm feeling brake pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove both battery cables from battery.
(3) Remove the battery thermal guard and the bat-
tery from the battery tray.
(4) Remove the air inlet resonator and hoses as an
assembly from the throttle body and air cleaner
housing (Fig. 111)
(5) If vehicle is equipped with speed control,
unplug wiring harness connector from the speed con-
trol servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery
tray.
(6) Remove bolt attaching the speed control servo
bracket to the battery tray. Slide the bracket forward
to unhook it from the battery tray and remove.
(7) Remove the 2 bolts and the nut (Fig. 112)
attaching the battery tray to the body of the vehicle.
(8) Remove wiring harness connector from brake
fluid level sensor in master cylinder fluid reservoir
(Fig. 113).
(9) Clean the area where the master cylinder
assembly attaches to the power brake booster. Use
only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Fig. 109 Retaining Clip Installed On Brake Pedal Pin
Fig. 110 Vacuum Seal Installed On Master Cylinder
NSBRAKES 5 - 49
REMOVAL AND INSTALLATION (Continued)