1996 CHRYSLER VOYAGER service interval

LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION................... 1
JUMP STARTING, HOISTING AND TOWING.... 7MAINTENANCE SCHEDULES................ 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS........... 1
FLUID CAPACITIES....................... 2
INTERNATIONAL SYMBOLS................ 1INTRODUCTION......................... 1
PARTS AND LUBRICANT
RECOMMENDATIONS.................... 1
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.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation
recommends that only Mopartbrand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
inspection and fill locations (Fig. 1).
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organization should be used to service a Chrysler
Corporation vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 2)
²National Lubricating Grease Institute (NLGI)
(Fig. 3)
Fig. 1 International Symbols
NSLUBRICATION AND MAINTENANCE 0 - 1

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

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

hydrometer reading. Always correct the specific grav-
ity for temperature variation. Test the specific grav-
ity of the electrolyte in each battery cell. Refer to the
information with the Hydrometer.
Example 1:
²Hydrometer reading: 1.260
²Electrolyte temperature: -7ÉC (20ÉF)
²Subtract specific gravity: -0.019
²Correction specific gravity: 1.241
Example 2:
²Hydrometer reading: 1.225
²Electrolyte temperature: -38ÉC (100ÉF)
²Add specific gravity: +0.013
²Correction specific gravity: 1.238
A fully charged relatively new battery has a spe-
cific gravity reading of 1.285 plus 0.015 or minus
0.010.
If the specific gravity of all cells is above 1.235, but
variation between cells is more than 50 points
(0.050), it is an indication that the battery is unser-
viceable.
If the specific gravity of one or more cells is less
than 1.235, recharge the battery at a rate of approx-
imately 5 amperes. Continue charging until three
consecutive specific gravity tests, taken at one-hour
intervals, are constant.
If the cell specific gravity variation is more than 50
points (0.050) at the end of the charge period, replace
the battery.When the specific gravity of all cells is above 1.235
and variation between cells is less than 50 points
(0.050), the battery may be tested under heavy load.
DIAGNOSIS AND TESTING
BATTERY DISCHARGING
CAUSE OF BATTERY DISCHARGING
It is normal to have a small 5 to 25 milliamperes
continuous electrical draw from the battery. This
draw will take place with the ignition in the OFF
position, and the courtesy, dome, storage compart-
ments, and engine compartment lights OFF. The con-
tinuous draw is due to various electronic features or
accessories that require electrical current with the
ignition OFF to function properly. When a vehicle is
not used over an extended period of approximately 20
days the IOD fuse should be disconnected. The fuse
is located in the power distribution center. Disconnec-
tion of this fuse will reduce the level of battery dis-
charge. Refer to Battery Diagnosis and Testing Chart
and to the proper procedures.
ABNORMAL BATTERY DISCHARGING
²Corroded battery posts, cables or terminals.
²Loose or worn generator drive belt.
²Electrical loads that exceed the output of the
charging system due to equipment or accessories
installed after delivery.
²Slow driving speeds in heavy traffic conditions
or prolonged idling with high-amperage electrical
systems in use.
²Defective electrical circuit or component causing
excess Ignition Off Draw (IOD). Refer to Battery
Ignition Off Draw (IOD).
²Defective charging system.
²Defective battery.
BATTERY IGNITION OFF DRAW
High current draw on the battery with the ignition
OFF will discharge a battery. After a dead battery is
serviced the vehicle Ignition Off Draw (IOD) should
be checked. Determine if a high current draw condi-
tion exists first check the vehicle with a test lamp.
(1) Verify that all electrical accessories are OFF.
²Remove key from ignition switch
²Turn off all lights
²Liftgate and glove box door is closed
²Sun visor vanity lights are OFF
²All doors are closed
²Allow the Illuminated Entry System to time out
in approximately 30 seconds, if equipped.
(2) Disconnect battery negative cable (Fig. 4).
Fig. 3 Battery Hydrometer
NS/GSBATTERY 8A - 3
DESCRIPTION AND OPERATION (Continued)

²available manifold vacuum
²barometric pressure
²engine coolant temperature
²engine RPM
²intake air temperature (2.4L only)
²throttle position
The PCM also regulates the fuel injection system.
Refer to the Fuel Injection sections of Group 14.
IGNITION SYSTEM
NOTE: The 2.4, 3.0 and 3.3/3.8L engines use a fixed
ignition timing system. Basic ignition timing is not
adjustable. All spark advance is determined by the
Powertrain Control Module (PCM).
The distributorless ignition system used on 2.4 and
3.3/3.8L engines is refered to as the Direct Ignition
System (DIS). The system's three main components
are the coil pack, crankshaft position sensor, and
camshaft position sensor. The crankshaft position
sensor and camshaft position sensor are hall effect
devices.
The 3.0L engine uses a distributor, crankshaft sen-
sor and ignition coil. The system's main components
are the distributor, distributor pickup, camshaft sig-
nal, crankshaft signal and ignition coil.
SPARK PLUGSÐ2.4/3.0L
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O - Lubrication and Maintenance.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled. Refer to the Spark Plug Condition section of
this group. After cleaning, file the center electrode
flat with a small flat point file or jewelers file. Adjust
the gap between the electrodes (Fig. 2) to the dimen-
sions specified in the chart at the end of this section.
Special care should be used when installing spark
plugs in the 2.4L cylinder head spark plug wells. Be
sure the plugs do not drop into the wells, damage to
the electrodes can occur.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head. Tighten spark plugs
to 28 N´m (20 ft. lbs.) torque.SPARK PLUGSÐ3.3/3.8L
The 3.3/3.8L engines utilize platinum spark plugs.
Refer to the maintenance schedule in Group 0 of this
service manual.
Fig. 1 Powertrain Control Module
Fig. 2 Setting Spark Plug Electrode Gap
8D - 2 IGNITION SYSTEMNS
GENERAL INFORMATION (Continued)

All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O - Lubrication and Maintenance.
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
fouled. Refer to the Spark Plug Condition section of
this group.
The spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal
driving conditions per schedule A in this manual. The
spark plugs have a recommended service life of
75,000 miles for serve driving conditions per schedule
B in this manual. A thin platinum pad is welded to
both electrode ends as show in (Fig. 3). Extreme care
must be used to prevent spark plug cross threading,
mis-gaping and ceramic insulator damage during
plug removal and installation.
CAUTION: Never attempt to file the electrodes or
use a wire brush for cleaning platinum plugs. This
would damage the platinum pads which would
shorten spark plug life.
Apply a very small amount of anti-seize compound
to the threads when reinstalling the vehicle's original
spark plugs that have been determined good.Do not
apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conduc-
tive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-
seize compound doesn't make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the platinum
electrodes or adjust the gap on platinum spark plugs
without reading the 3.3/3.8L Spark Plug Gap Mea-
surement procedures in this section.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head. Tighten spark plugs
to 28 N´m (20 ft. lbs.) torque.
Due to the engine packaging environment for the
3.3/3.8L engines, extreme care should be used wheninstalling the spark plugs to avoid cross threading
problems.
3.3/3.8L SPARK PLUG GAP MEASUREMENT
CAUTION: The Platinum pads can be damaged dur-
ing the measurement of checking the gap if extreme
care is not used.
²USE ONLY A TAPER GAP GAUGE (Fig. 2)
²Never force the gap gauge through the platinum
pads. Only apply enough force until resistance is felt.
²Never use a wire brush or spark plug cleaner
machine to clean platinum spark plugs
²Use an OSHA approved air nozzle when drying
gas fouled spark plugs.
If gap adjustment is required of platinum plug,
bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool
and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may dam-
age the platinum tip.
SPARK PLUG CABLE
Spark Plug cables are sometimes referred to as
secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack, distributor
(3.0L), to individual spark plugs at each cylinder. The
resistive spark plug cables are of nonmetallic con-
struction. The cables provide suppression of radio fre-
quency emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil, distributor cap towers (3.0L), and
spark plugs. Terminals should be fully seated. The
insulators should be in good condition and should fit
tightly on the coil, distributor (3.0L) and spark plugs.
Spark plug cables with insulators that are cracked or
torn must be replaced.
Fig. 3 Platinum Pads
NSIGNITION SYSTEM 8D - 3
GENERAL INFORMATION (Continued)

REMOTE KEYLESS ENTRY
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 5
VEHICLE ACCESS CODE (VAC)
PROGRAMMING........................ 5
DIAGNOSIS AND TESTING
RKE DIAGNOSTICS....................... 5
SERVICE PROCEDURES
HORN CHIRP DISABLE OR ENABLE.......... 6REMOVAL AND INSTALLATION
RKE MODULE........................... 6
ADJUSTMENTS
PROGRAMMING RKE MODULE.............. 6
SPECIFICATIONS
RKE TRANSMITTER BATTERY.............. 6
RKE TRANSMITTER RANGE................ 6
DESCRIPTION AND OPERATION
INTRODUCTION
The key fob transmitter has three buttons to actu-
ate and program the Remote Keyless Entry (RKE)
system (Fig. 1).
²UNLOCK: Pressing the UNLOCK button once
will unlock the driver door and activate the illumi-
nated entry system and disarm Vehicle Theft Secu-
rity System, if equipped. Pressing the UNLOCK
button twice within five seconds will unlock all doors
and activate the illuminated entry system.
²LOCK: Pressing the LOCK button locks all
doors and sounds horn (chirp) and arm the Vehicle
Theft Security System. The chirp verifies the door
lock operation.
²PANIC: Pressing the PANIC button sounds the
horns at half second intervals, flashes the exterior
lamps, and turns ON the interior lamps. The panic
alarm will remain on for three minutes, or until the
PANIC button is actuated again or the ignition
switch is turned to the RUN position.
²The Remote Keyless Entry Module is capable of
retaining the transmitter Vehicle Access Code(s)
(VAC) in its memory even after vehicle power has
been interrupted.
²The RKE system activates the optional memory
seat and mirror system, if equipped. Two primary
key fob transmitters can be programmed to actuate
memory seat and mirror setting 1 or 2. Two addi-
tional key fob transmitters can be added, but they
will not be able to operate the memory seat and mir-
ror system. Refer to Group 8R, Power Seats and
Group 8T, Power Mirrors for memory system infor-
mation.
VEHICLE ACCESS CODE (VAC) PROGRAMMING
The RKE module is capable of retaining up to four
different Vehicle Access Codes. Whenever the vehicle
battery power is interrupted the RKE Module willretain all vehicle access codes in its memory. When
replacing or adding a key fob transmitter (maximum
4) a functional key fob transmitter is required to pro-
gram the RKE Module to accept the new Vehicle
Access Code. If a functional key fob transmitter is
not available, a scan tool (DRB) can be used to pro-
gram the RKE Module. Refer to the proper Body
Diagnostic Procedures manual for Vehicle Access
Code programming procedures using a scan tool.
DIAGNOSIS AND TESTING
RKE DIAGNOSTICS
Refer to Group 8W, Wiring Diagrams for circuit
information and component locations. Refer to the
proper Body Diagnostic Procedures manual for test-
ing the Remote Keyless Entry system using a scan
tool (DRB). Also refer to other interrelated systems
groups within this manual:
²Group 8Q, Vehicle Theft Security System
²Group 8R, Power Seats
²Group 8T, Power Mirrors
Fig. 1 Key Fob Transmitter
NSPOWER DOOR LOCKS 8P - 5

kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 14) (Fig. 15).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9)
Connect connector to its mating half/component.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at
1/2 inch intervals (Fig. 16).(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 16).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push down on the yellow connector locking tab
to release the terminals (Fig. 17).
(4) Using special tool 6932, push the terminal to
remove it from the connector (Fig. 18).
Fig. 14 Terminal Removal
Fig. 15 Terminal Removal Using Special Tool
Fig. 16 Stagger Cutting Wires
8W - 01 - 12 8W-01 GENERAL INFORMATIONNS/GS
SERVICE PROCEDURES (Continued)