1996 CHRYSLER VOYAGER recommended oil

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)

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)

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)

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

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

STEERING KNUCKLE
The front suspension knuckle is not a repairable
component of the vehicles front suspensionIT MUST
BE REPLACED.If bent, broken or damaged in any
way, do not attempt to straighten or repair the steer-
ing knuckle.
Service replacement of the front hub/bearing
assembly can be done with the front steering knuckle
remaining on the vehicle.
LOWER CONTROL ARM
If damaged, the lower control arm casting is ser-
viced only as a complete component. Inspect lower
control arm for signs of damage from contact with
the ground or road debris. If lower control arm shows
any sign of damage, inspect lower control arm for
distortion.Do not attempt to repair or straighten
a broken or bent lower control arm.
The serviceable components of the lower control
arm are: the ball joint assembly, ball joint assembly
grease seal and control arm bushings. Inspect both
control arm bushings for severe deterioration, and
replace if required. Inspect ball joint per inspection
procedure in this section of the service manual and
replace if required. Service procedures to replace
these components are detailed in the specific compo-
nent removal and installation sections in this group
of the service manual.
BALL JOINT (LOWER)
With the weight of the vehicle resting on the road
wheels, grasp the grease fitting as shown in (Fig. 5)
and with no mechanical assistance or added force
attempt to rotate the grease fitting.
If the ball joint is worn the grease fitting will
rotate easily. If movement is noted, replacement of
the ball joint is recommended.
STABILIZER BAR
Inspect for broken or distorted sway bar bushings,
bushing retainers, and worn or damaged sway bar to
strut attaching links. If sway bar to front suspension
cradle bushing replacement is required, bushing can
be removed from sway bar by opening slit and peel-
ing bushing off sway bar.
HUB AND BEARING ASSEMBLY
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
bearing assembly will produce noise and vibration
when worn or damaged. The noise will generally
change when the bearings are loaded. A road test of
the vehicle is normally required to determine the
location of a worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
Where axle bearing damage is slight, the noise is
usually not noticeable at speeds above 30 m.p.h..
SERVICE PROCEDURES
SUSPENSION CRADLE THREAD REPAIR
PROCEDURE
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.
The threaded holes in the front suspension cradle,
if damaged, can repaired by installing a Heli-Coilt
thread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the suspension crossmember to be repaired,
eliminating the need to replace the crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
Fig. 5 Checking Ball Joint Wear
2 - 12 SUSPENSIONNS
DIAGNOSIS AND TESTING (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

(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)