1996 CHRYSLER VOYAGER jacking

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)

BRAKES
CONTENTS
page page
ANTILOCK BRAKE SYSTEM ±
TEVES MARK-20....................... 85BASE BRAKE SYSTEM..................... 3
GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
BASE BRAKE SYSTEM COMPONENT
DESCRIPTION......................... 1GENERAL VEHICLE SERVICE CAUTIONS...... 1
GENERAL INFORMATION
GENERAL VEHICLE SERVICE CAUTIONS
CAUTION: At no time when servicing a vehicle, can a
sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled into
the front shock tower in the area shown in (Fig. 1), for
the installation of any metal fasteners into the shock
tower. Because of the minimum clearance in this area
(Fig. 1), installation of metal fasteners could damage
the coil spring coating and lead to a corrosion failure
of the spring. If a plastic clip is missing, or is lost or
broken during servicing a vehicle, replace only with
the equivalent part listed in the Mopar parts catalog.
CAUTION: Only the recommended jacking or hoisting
positions for this vehicle are to be used whenever it is
necessary to lift a vehicle. Failure to raise a vehicle
from the recommended locations could result in lifting
a vehicle by the hydraulic control unit mounting
bracket. Lifting a vehicle by the hydraulic control unit
mounting bracket will result in damage to the mount-
ing bracket and the hydraulic control unit.
BASE BRAKE SYSTEM COMPONENT DESCRIPTION
The standard brake system on this vehicle consists
of the following components:
²Double pin floating caliper disc front brakes.
²Double pin floating caliper rear disc brakes on
all wheel drive applications.²Rear automatic adjusting drum brakes.
²Master cylinder with brake fluid level sensor.
²Vacuum booster.
²Height sensing proportioning valve (non-antilock
brake applications)
²Non-height sensing proportioning valve (antilock
brake applications)
The brakes hydraulic system on both non-antilock
and antilock brake systems is diagonally split (Fig. 2)
(Fig. 3). A diagonally split brake system means the
left front and right rear brakes on one hydraulic sys-
tem and the right front and left rear on the other.
Fig. 1 Shock Tower To Spring Minimum Clearance
Area
NSBRAKES 5 - 1

If the brake system is to be bled using pressurized
bleeding equipment, refer to Bleeding Brake System
in the Service Adjustments section at the beginning
of this group for proper equipment usage and proce-
dures.
(1) Assemble and install all brake system compo-
nents on the vehicle making sure all hydraulic fluid
lines are installed and properly torqued.
(2) Connect the DRB Diagnostics Tester to the
diagnostics connector. The Teves Mark 20 ABS diag-
nostic connector is located under the instrument
panel to the left of the steering column cover.
(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does,
remove them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYS-
TEM WEAR SAFETY GLASSES. A CLEAR BLEED
TUBE MUST BE ATTACHED TO THE BLEEDER
SCREWS AND SUBMERGED IN A CLEAR CON-
TAINER FILLED PART WAY WITH CLEAN BRAKE
FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY
FROM THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME
OUT OF THE BLEEDER SCREWS WHEN OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure as out-
lined in the Service Adjustments section of this
service manual.
(5) Using the DRB, go to the9Bleed ABS9routine.
Apply the brake pedal firmly and initiate the9Bleed
ABS9cycle one time. Release the brake pedal.
(6) Bleed the base brake system again, as in step
Step 4 above.
(7) Repeat steps Step 5 and Step 6 above until
brake fluid flows clear and is free of any air bubbles.
Check brake fluid level in reservoir periodically to
prevent reservoir from running low on brake fluid.
(8) Test drive the vehicle to be sure brakes are
operating correctly and that brake pedal is solid.
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS
CAUTION: Review this entire section prior to per-
forming any mechanical work on a vehicle equipped
with the ITT Tevis Mark 20 ABS brake system. This
section contains information on precautions per-
taining to potential component damage, vehicle
damage and personal injury which could result
when servicing an ABS equipped vehicle.
CAUTION: Only the recommended jacking or hoist-
ing positions for this vehicle are to be used when-ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
result in lifting a vehicle by the hydraulic control
unit mounting bracket. Lifting a vehicle by the
hydraulic control unit mounting bracket will result
in damage to the mounting bracket and the hydrau-
lic control unit.
CAUTION: Certain components of the ABS System
are not intended to be serviced individually.
Attempting to remove or disconnect certain system
components may result in improper system opera-
tion. Only those components with approved
removal and installation procedures in this manual
should be serviced.
CAUTION: Brake fluid will damage painted sur-
faces. If brake fluid is spilled on any painted sur-
faces, wash off with water immediately.
CAUTION: When performing any service procedure
on a vehicle equipped with ABS do not apply a 12
volt power source to the ground circuit of the pump
motor in the CAB. Doing this will damage the pump
motor and will require replacement of the HCU.
The following are general cautions which should be
observed when servicing the ABS system and/or
other vehicle systems. Failure to observe these pre-
cautions may result in ABS System component dam-
age.
If welding work is to be performed on the vehicle,
using an electric arc welder, the CAB connector
should be disconnected during the welding operation.
The CAB 25 way connector connector should never
be connected or disconnected with the ignition switch
in the ON position.
Many components of the ABS System are not ser-
viceable and must be replaced as an assembly. Do not
disassemble any component which is not designed to
be serviced.
HYDRAULIC CONTROL UNIT
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
(3) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
5 - 100 BRAKESNS
SERVICE PROCEDURES (Continued)

API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conforms to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 5).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either
ENERGY CONSERVING or ENERGY CONSERV-
ING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
Fig. 5 Temperature/Engine Oil Viscosity
Fig. 6 Engine Oil Container Standard Notations
9 - 6 ENGINENS
GENERAL INFORMATION (Continued)

ENGINE OIL CHANGE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.
(3) Hoist vehicle. Refer to Hoisting and Jacking
Recommendations.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan (Fig. 5). Inspect drain plug
threads for stretching or other damage. Replace
drain plug if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL
ENGINE OIL QUALITY
Use only oils conforming to API (American Petro-
leum Institute) quality SG/CD, or CCMC G4. Use
only Diesel engine oil meeting standardMIL-2104C
or API service classificationSG/CD or CCMM PD1.
OIL VISCOSITY
Grade 15W-40 is recommended for temperatures
between +35ÉC to ±10ÉC (95ÉF to 14ÉF). Low viscosity
oils must have the proper API quality or the CCMC
G5 designation. Low viscosity oils are preferred when
minimum temperatures consistently fall below ±12ÉC
(10ÉF).
ENGINE OIL FILTER CHANGE
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the oil filter base (Fig. 6).
(4) When filter separates from base, tip gasket end
upward to minimize oil spill. Remove filter from vehi-
cle.
(5) With a cloth, wipe clean the gasket sealing sur-
face of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto the base. When gasket
makes contact with sealing surface, hand tighten fil-
ter one full turn, do not over tighten.
Fig. 5 Oil Drain Plug
Fig. 6 Oil Filter
9 - 48 ENGINENS/GS
SERVICE PROCEDURES (Continued)