1996 CHRYSLER VOYAGER tires

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

Camber adjustment is allowed in the event that a
vehicle is involved in an accident and after repairs
are made meeting manufacturers tolerance specifica-
tions, the camber setting will not meet manufactur-
ers specifications. If camber adjustment is required,
refer to the following Service Camber Adjustment
Procedure for the required steps to be followed.
CAUTION: Do not attempt to modify any suspen-
sion or steering components to meet vehicle align-
ment specifications, by heating and or bending.
Alignment checks and adjustments should be made
in the following sequence.
(1) Camber
(2) ToeCamberis the number of degrees the top of the
wheel and tire assembly is tilted inboard or outboard
from a true vertical line. Inboard tilt is negative cam-
ber. Outboard tilt is positive camber (Fig. 1).
Excessive camber is a tire wear factor: negative
camber causes wear on the inside of the tires tread
surface, while positive camber causes wear to the
outside of the tires tread surface. See Front Wheel
Drive Specifications forCamber.settings.
To eis measured in degrees or inches and is the
distance the front edges of the tires are closer (or far-
ther apart) than the rear edges. See Front Wheel
Drive Specifications forToe.settings.
Fig. 1 Front Suspension Alignment Angles
2 - 2 SUSPENSIONNS
DESCRIPTION AND OPERATION (Continued)

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Growl Or Grinding On
Turns1. Defective wheel bearing 1. Replace wheel bearing
2. Engine mount grounding 2. Check for motor mount hitting
frame rail and reposition engine as
required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
6. Worn tires 6. Replace tires
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Front End Clunk Or Snap On Turns 1. Loose lug nuts 1. Verify wheel lug nut torque
2. Worn or broken C/V joint 2. Replace C/V joint
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body
attachment7. Tighten strut attachment to
specified torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With Vehicle
Going Straight At A Constant Speed1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
4. Worn or defective transaxle gears
or bearings4. Replace transaxle gears or
bearings
Front End Growl Or Grinding With
Vehicle Going Straight At A
Constant Speed1. Engine mount grounding 1. Reposition engine as required
2. Worn or broken C/V joint 2. Replace C/V joint
Front End Whine When
Accelerating Or Decelerating1. Worn or defective transaxle gears
or bearings1. Replace transaxle gears or
bearings
Front End Clunk When Accelerating
Or Decelerating1. Worn or broken engine mount 1. Replace engine mount
2. Worn or defective transaxle gears
or bearings2. Replace transaxle gears or
bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
4. Worn or broken C/V joint 4. Replace C/V joint
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
NSSUSPENSION 2 - 3

CONDITION POSSIBLE CAUSES CORRECTION
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended
pressure
2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft
coupling6. Replace steering coupler
7. Excessive friction in strut upper
bearing7. Replace strut bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended
pressure
2. Radial tire lead 2. Perform lead correction procedure
3. Incorrect front wheel camber 3. Check and reset front wheel
camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free Play 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to
specified torque
4. Loose or worn steering shaft
coupler4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive
belt4. Correctly adjust power steering
pump drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering
coupler7. Replace steering coupler
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct
the wheel alignment factors. The following part
inspection and the necessary corrections should be
made to those parts which influence the steering of
the vehicle.
(1) Check and inflate all tires to recommended
pressure. All tires should be the same size and in
good condition and have approximately the same
wear. Note the type of tread wear which will aid in
diagnosing, see Wheels and Tires, Group 22.
(2) Check front wheel and tire assembly for radial
runout.
(3) Inspect lower ball joints and all steering link-
age for looseness.
(4) Check for broken or sagged front and rear
springs.(5) Check vehicle ride height to verify it is within
specifications.
(6) AlignmentMUSTonly be checked after the
vehicle has the following areas inspected and or
adjusted. Recommended tire pressures, full tank of
fuel, no passenger or luggage compartment load and
is on a level floor or a properly calibrated alignment
rack.
SERVICE PROCEDURES
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
PROCEDURE
CASTER AND CAMBER
Front suspension Caster and Camber settings on
this vehicle are determined at the time the vehicle is
designed. This is done by determining the precise
2 - 4 SUSPENSIONNS
DIAGNOSIS AND TESTING (Continued)

mounting location of the vehicle's suspension compo-
nents throughout the design and assembly processes
of the vehicle. This is called a Net Build vehicle and
results in no normal requirement to adjustment the
Caster and Camber after a vehicle is built or when
servicing the suspension components. Thus Caster
and Camber are not normally considered an adjust-
able specification when performing an alignment on
this vehicle. Though Caster and Camber are not
adjustable they should be checked during the align-
ment procedure to ensure they meet the manufactur-
ers specifications.
If front camber does not meet the vehicle align-
ment specifications, it can be adjusted using a Mopar
Service Kit developed to allow for camber adjust-
ment. If a vehicle's front camber does not meet
required specifications, the vehicles suspension com-
ponents should be inspected for any signs of damage
or bending and the vehicle ride height should be
checked to verify it is within required specification.
This inspection must be done before using the
Mopar Service Kit for setting camber to the
vehicle specification.
CAUTION: Do not attempt to adjust the vehicles
Caster or Camber by heating, bending or by per-
forming any other modification to the vehicle's front
suspension components.
(1) Correctly position the vehicle on the alignment
rack. Then install all required alignment equipment
on the vehicle, per the alignment equipment manu-
facturers specifications.
NOTE: Prior to reading each alignment specifica-
tion, front and rear of vehicle should be jounced an
equal number of times. Induce jounce (rear first
then front) by grasping center of bumper and jounc-
ing each end of vehicle an equal number of times.
Bumper should always be released when vehicle is
at the bottom of the jounce cycle.
(2) Correctly jounce vehicle and then read the
vehicle's current front and rear alignment settings.
Compare the vehicle's current alignment settings to
the vehicle specifications for camber, caster and Toe-
in. See Alignment Specifications in this group of the
service manual for the required specifications.If
front and rear camber readings are within
required specifications proceed to step Step 3
for the Toe-in adjustment procedure if
required. If Camber readings are not within
specifications refer to step Step 1 in the front
camber adjustment cam bolt adjustment proce-
dure.CAMBER ADJUSTMENT CAM BOLT PACKAGE INSTALLATION
PROCEDURE
(1) If the front camber readings obtained are not
within the vehicle's specifications, use the following
procedure and the Mopar Clevis Bolt Service Kit to
provide camber adjustment. The kit contains 2 flange
bolts, 2 cam bolts, and 2 dog bone washers. These
components of the service kit are necessary to assem-
ble the strut to the steering knuckle, after modifica-
tion of the strut clevis bracket.
(2) Verify that the strut and steering knuckle are
not bent or otherwise damaged. If either component
is bent or show other signs of damage, replace
required component(s) and check the camber setting
again. Refer to Strut Damper Assembly Service in
this group of the service manual for the required
strut replacement procedure.
(3) If no component is bent or damaged, use the
following procedure for modifying the strut clevis
bracket and adjusting the camber setting.
(4) Raise front of vehicle until tires are not sup-
porting the weight of the vehicle. Then remove wheel
and tire assembly from the location on the vehicle
requiring the strut to be modified.
CAUTION: When removing the steering knuckle
from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of
the steering knuckle assembly be supported by the
brake flex hose when removed from the strut
assembly. If necessary use a wire hanger to sup-
port the steering knuckle assembly or if required
remove the brake flex hose from the caliper assem-
bly.
CAUTION: The steering knuckle strut assembly
attaching bolts are serrated and must not be turned
during removal. Remove nuts while holding bolts
stationary in the steering knuckles.
(5) Remove the top and bottom, strut clevis
bracket to steering knuckle attaching bolts (Fig. 2)
and discard. Separate the steering knuckle from the
strut clevis bracket and position steering knuckle so
it is out of the way of the strut.
CAUTION: When slotting the bottom mounting
hole on the strut clevis bracket, do not enlarge the
hole beyond the indentations (Fig. 3) on the sides
of the strut clevis bracket.
NSSUSPENSION 2 - 5
SERVICE PROCEDURES (Continued)

CAUTION: Wheel bearing damage will result if after
loosening hub nut, vehicle is rolled on the ground
or the weight of the vehicle is allowed to be sup-
ported by the tires.
(5) With the vehicle's brakes applied to keep hub
from turning,loosen and removethe stub axle to
hub nut.
(6) Remove the 2 front disc brake caliper to steer-
ing knuckle attaching bolts (Fig. 13).
(7) Remove the disc brake caliper from the steer-
ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined
abutment on steering knuckle (Fig. 14).
(8) Support disc brake caliper assembly by using a
wire hook and suspending it from the strut assembly
(Fig. 15).Do not allow the brake caliper assem-
bly to hang by the brake flex hose.
Fig. 11 Hub/Bearing To Stub Axle Retaining Nut
Fig. 12 Wave Washer
Fig. 13 Front Disc Brake Caliper Attaching Bolts
Fig. 14 Brake Caliper Mounting To Steering Knuckle
Fig. 15 Correctly Supported Disc Brake Caliper
NSSUSPENSION 2 - 15
REMOVAL AND INSTALLATION (Continued)

CAUTION: Wheel bearing damage will result if
after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be
supported by the tires.
(3) With the aid of a helper applying the brakes to
keep the front hub from turning,loosen but do not
removethe hub nut.The hub and driveshaft are
splined together through the knuckle (bearing)
and retained by the hub nut.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(5) Remove wheel lug nuts, and front tire and
wheel assembly.
(6) Remove front disc brake caliper to steering
knuckle attaching bolts. (Fig. 54).
(7) Remove disc brake caliper assembly from steer-
ing knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle, and then
removing bottom of caliper out from under machined
abutment. (Fig. 55)
(8) Support disc brake caliper assembly using a
wire hook, (Fig. 56)do not hang caliper assembly
by hydraulic hose.
(9) Remove the braking disc from the front hub/
bearing assembly.
(10) Remove the retaining nut and the washer
(Fig. 57) from the end of the stub axle.
(11) Remove the four hub and bearing assembly
mounting bolts from the rear of steering knuckle
(Fig. 58).
(12) Remove the hub and bearing assembly from
the steering knuckle (Fig. 59).
Fig. 54 Front Disc Brake Caliper Mounting Bolts
Fig. 55 Brake Caliper Assembly Removal/Installation
Fig. 56 Supporting Brake Caliper
Fig. 57 Hub/Bearing To Stub Axle Retaining Nut And
Washer
2 - 26 SUSPENSIONNS
REMOVAL AND INSTALLATION (Continued)