2004 CHRYSLER VOYAGER engine coolant

SCHEDULE A - EXPORT ONLY
Kilometers 12 000 24 000 36 000 48 000 60 000 72 000
(Miles) (7,500) (15,000) (22,500 (30,000) (37,500) (45,000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter,
replace if necessary. *XXX X X
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Inspect the tie rod ends and boot
seals.X
Replace the air conditioning filter. X X X
Kilometers 84 000 96 000 108 000 120 000 132 000 144 000
(Miles) (52,500) (60,000) (67,500) (75,000) (82,500) (90,000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter,
replace if necessary. *X XXX
Replace theengine air cleaner filter.XX
Replace thespark plugson 2.4 liter
engines.XX
Replace theignition cableson 2.4
liter engines.X
Inspect and adjust the power steering
pump belt tension on 2.4 liter engines.XX
Inspect the tie rod ends and boot
seals.XX
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check thePCV valveand replace, if
necessary.*XX
Inspect the serpentine drive belt on 3.3
liter engines, replace if necessary. ³XX X
Flush and replace the engine coolant
at 60 months, regardless of mileage.X
Replace the air conditioning filter. X X X
0 - 16 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 2.4 liter
engines.X
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.XX
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check and replace thePCV valve,if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
engines, replace if necessary. ³XX
Replace thespark plugs3.3 liter engines. X
Replace theignition cables3.3 liter
engines.X
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.X
Replace theengine timing belton 2.4 liter
engines only.X
Replace the air conditioning filter. X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
RSLUBRICATION & MAINTENANCE0-17
MAINTENANCE SCHEDULES (Continued)

Kilometers 149 000 154 000 158 000 160 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000)
Change engine oil and engine
oil filter.XXX X X
Inspect the brake linings. X
Inspect the engine air cleaner
filter, replace if necessary. *XXXXX
Replace theengine air
cleaner filter*X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.X
Inspect the generator belt on
2.4 liter engines, replace if
necessary.X
Inspect engine accessory
drive belts on 3.3 liter
engines, replace if necessary.
³X
Change the manual
transmission fluid.X
Change the All Wheel Drive
(AWD) power transfer unit,
overrunning clutch and rear
carrier fluid. (See note at the
end of this chart)X
Flush and replace the engine
coolant at 60 months or
100,000 miles.X
Replace the air conditioning
filter.X
0 - 22 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

DESCRIPTION ± DIESEL ENGINES ± EXPORT
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under
Schedule9B9.
Second is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Extensive engine idling.
²Driving in dusty conditions.
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 minutes after
a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground willimprove the accuracy of the oil level reading. Add oil
only when the level is at or below the ADD or MIN
mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check the tire pressure and look for unusual
wear or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant deaeration bot-
tle, brake master cylinder and transmission, add as
needed.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Inspect engine accessory drive belts. Replace as
necessary.
²Inspect for the presence of water in the fuel fil-
ter/water separator unit.
²Rotate the tires at each oil change interval (20
000 km).
SCHEDULE A - DIESEL ENGINES
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000
km
Change engine oil and engine oil filter.XXXX X
Inspect engine air filter element. Replace as
necessary.XX X
Replace engine air filter element X X
Replace fuel filter/water separator unit.XXXX X
Inspect timing belt tensioner and replace if
necessary. ³X
Replace engine timing belt and idler
pulleys.X
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings.XXXX X
0 - 24 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 120 000
km140 000
km160 000
km180 000
km
Change engine oil and engine oil filter. X X X X
Inspect engine air filter element. Replace as necessary. X X
Inspect accessory drive belts and replace if necessary. X
Replace engine air filter element X X
Replace fuel filter/water separator unit. X X X X
Flush and replace engine coolant. X
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings. X X X X
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.³ Replace if there is superficial wear, bearing clear-
ance, or evident grease leakage.
SCHEDULE B - DIESEL ENGINES
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
²Extensive engine idling.
²Driving in dusty conditions.²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Change engine oil and engine oil filter.XXXX X
Inspect engine air filter element. Replace as
necessary.XX X
Replace engine air filter element X X
Replace fuel filter/water separator unit. X X
Check front end alignment. X X
Change the manual transaxle fluid. X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings.XXXX X
RSLUBRICATION & MAINTENANCE0-25
MAINTENANCE SCHEDULES (Continued)

Kilometers 60 000
km70 000 km 80 000 km 90 000 km 100 000
km
Change engine oil and engine oil filter. X X X X X
Inspect engine air filter element. Replace as
necessary.XX
Replace engine air filter element X X X
Replace fuel filter/water separator unit. X X X
Inspect timing belt tensioner and replace if
necessary. ³X
Replace engine timing belt and idler pulleys. X
Check front end alignment. X X
Change the manual transaxle fluid. X X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings. X X X X X
Kilometers 110 000
km120 000
km130 000
km140 000
km150 000
km160 000
km
Change engine oil and engine
oil filter.XXXXX X
Inspect engine air filter
element. Replace as
necessary.XXX
Inspect accessory drive belts
and replace if necessary.X
Replace engine air filter
elementXX X
Replace fuel filter/water
separator unit.XX X
Flush and replace engine
coolant.X
Check front end alignment. X X X
Inspect the tie rod ends and
boot seals.XX
Inspect the brake linings. XXXXX X
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
³ Replace if there is superficial wear, bearing clear-
ance, or evident grease leakage.WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
0 - 26 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Use only brake fluid that was stored in a tightly-
sealed container.
DO NOTuse petroleum-based fluid because seal
damage will result. Petroleum based fluids would be
items such as engine oil, transmission fluid, power
steering fluid etc.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications (DOT 4 and DOT 4+ are
acceptable) and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage
in the vehicle brake system. Use only MopartBrake
Fluid or 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 of brake fluid 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, etc.
JUNCTION BLOCK
DESCRIPTION - NON-ABS JUNCTION BLOCK
A junction block is used on vehicles that are not
equipped with antilock brakes (ABS). The junction
block mounts in the same location as the integrated
control unit (ICU) does on vehicles equipped with
ABS. This allows for use of the same brake tube con-
figuration on all vehicles. The junction block is
located on the driver's side of the front suspension
cradle/crossmember below the master cylinder (Fig.
45).
It has six threaded ports to which the brake tubes
connect. Two are for the primary and secondary
brake tubes coming from the master cylinder. The
remaining four are for the chassis brake tubes going
to each brake assembly.
OPERATION - NON-ABS JUNCTION BLOCK
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four chassis brake tubes leading to the
brakes at each wheel. Since the junction blockmounts in the same location as the ABS integrated
control unit (ICU), it allows for the common use of
brake tubes going to the brakes whether the vehicle
is equipped with or without ABS.
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
may appear to be the same, they are not. They are
unique to each brake system application.
REMOVAL - NON-ABS JUNCTION BLOCK
(1) Using a brake pedal depressor, move and lock
the brake pedal to a position past its first 1 inch of
travel. This will prevent brake fluid from draining
out of the master cylinder when the brake tubes are
removed from the junction block.
(2) Disconnect the battery negative cable.
(3) If the vehicle is equipped with speed control,
perform the following:
(a) Disconnect the battery positive cable.
(b) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(c) Disconnect the vacuum hose connector at the
tank built into the battery tray.
(d) Remove the screw securing the coolant filler
neck to the battery tray.
(e) Remove the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - REMOVAL).
(f) Remove the fasteners and move the speed
control servo off to the side, out of the way.
CAUTION: Before removing the brake tubes from
the junction block, the junction block and the brake
tubes must be thoroughly cleaned. This is required
to prevent contamination from entering the brake
hydraulic system.
(4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 45).
(5) Remove the primary and secondary brake
tubes from the top of the junction block.
(6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 45), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 45).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.).
(2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.).Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
RSBRAKES - BASE5-33
FLUID (Continued)

movement with rubber isolated suspension
crossmember.
(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.).
(4) If the vehicle is equipped with speed control,
perform the following:
(a) Install the speed control servo with its
mounting nuts.
(b) Connect the wiring harness to the speed con-
trol servo.
(c) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(d) Install the screw securing the coolant filler
neck to the battery tray.
(e) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(f) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery.
(7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(8) Road test the vehicle to verify proper operation
of the brake system.
MASTER CYLINDER
DESCRIPTION
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 46). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
For information on master cylinder application,
bore and type, view the following table:
BRAKE SYSTEMMASTER CYLINDER
BORE/TYPE
Disc/Drum - ABS23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Drum - Non-ABS23.8 mm (15/16 in.)
Conventional
Compensating Port
Disc/Disc - ABS25.4 mm (1.0 in.)
Conventional
Compensating Port
Disc/Disc ABS With
Traction Control25.4 mm (1.0 in.) Dual
Center Port
Fig. 45 NON-ABS JUNCTION BLOCK
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
Fig. 46 Master Cylinder And Booster Location
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
5 - 34 BRAKES - BASERS
JUNCTION BLOCK (Continued)