2004 CHRYSLER VOYAGER Service Manual

open hood brakes heater bonnet fuel tank removal coolant level

Page 17 of 2585

CHRYSLER VOYAGER 2004 Service Manual FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
For best results, a refueling pattern that alternates
bet

FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
For best results, a refueling pattern that alternates
between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recom-
mended that
²you do not switch when the fuel gauge indicates
less than 1/4 full
²you do not add less than 5 gallons when refuel-
ing
²you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in
driveability during warm up.
FFV STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0ÉF. In
the range of 0ÉF to 32ÉF, you may experience an
increase in the time it takes for your engine to start,
and a deterioration in driveability (sags and/or hesi-
tations) until the engine is fully warmed up.
Engine Operating on E-85 Fuel
If vehicle operates on E-85 fuel either full or part-
time, use only MopartFlexible Fuel 5W-30 engine oil
or an equivalent that meets DaimlerChrysler Stan-
dard MS-9214. Equivalent commercial Flexible Fuel
engine oils may be labeled as Multi-Fuel, Variable
Fuel, Flexible Fuel, etc. These engine oils may be
satisfactory if they meet the DaimlerChrysler Stan-
dard.
SAE 5W-30 engine oil is preferred for use in Flex-
ible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
CRUISING RANGE
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for these transaxles.NOTE: All transaxles have a common transmission
and differential sump. Filling the transaxle accom-
modates the differential as well.
TRANSMISSION FLUID
MopartATF+4 (Automatic Transmission Fluid) is
required in the 41TE automatic and T850 manual
transaxles. Substitute fluids can induce transmission
problems and/or failure.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
0 - 4 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

Page 18 of 2585

ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformu-
latedº gasoline. Reformulated gasoline contain oxy-
genates, and are specifically blended to reduce
vehicle emissions and improve air quality.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro-
vide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasoline free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may be
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle's catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
²The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)

Page 19 of 2585

CHRYSLER VOYAGER 2004 Service Manual NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASO

NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gel-
ling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and fol-
low the cold weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm up perfor-
mance.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
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
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC.
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Hous-
ing (front) and the Differential Carrier (rear).
The recommended lubricant for the Overrunning
Clutch Housing is MopartATF+4. The recommended
lubricant for the Differential Carrier is Mopart
80W-90 Gear and Axle Lubricant.
DESCRIPTION - AWD POWER TRANSFER UNIT
FLUID
The recommended lubricant for the AWD Power
Transfer Unit is MopartGear and Axle Lubricant
80W-90.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
Engine Oil* - 2.5 L (Diesel) 6.0 L (6.3 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with Auxiliary
Heater13.8 L (14.6 qts.)
Cooling System** - 3.3/3.8
L without Auxiliary Heater12.6 L (13.4 qts.)
Cooling System** - 3.3/3.8
L with Auxiliary Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-Speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
0 - 6 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

Page 20 of 2585

CHRYSLER VOYAGER 2004 Service Manual FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill point locations are located in
each applicable service manual section.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are locate

FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill point locations are located in
each applicable service manual section.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are located in each
applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 32É F (0É
C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90É F (32É C).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Second is ScheduleªAº. It is for vehicles that are
not operated under any of the conditions listed under
Schedule9B9.
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 will
improve 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 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 reservoir, 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 automatic transmission fluid level.
²Check the coolant level, hoses, and clamps.
Tire Rotation
²Rotate the tires at 6,000 miles (10 000 km).
SCHEDULE B
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
Change the automatic transmission fluid and filter
every 60,000 miles (96 000 km) if the vehicle is usu-
ally operated under one or more of the conditions
marked with anL.
²Day or night temperatures are below 32É F (0É
C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90É F (32É C).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
RSLUBRICATION & MAINTENANCE0-7

Page 21 of 2585

CHRYSLER VOYAGER 2004 Service Manual Miles 3, 000 6, 000 9, 000 12, 000 15, 000 18, 000
(Kilometers) (5 000 ) (10 000 ) (14 000) (19 000) (24 000) (29 000)
Change engine oil and engine oil
filter.XXXXX X
Inspect the brake linings. X X
In

Page 22 of 2585

CHRYSLER VOYAGER 2004 Service Manual Miles 39, 000 42, 000 45, 000 48, 000 51, 000 54, 000
(Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X

Page 23 of 2585

CHRYSLER VOYAGER 2004 Service Manual Miles 75, 000 78, 000 81, 000 84, 000 87, 000 90, 000
(Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)
Change engine oil and engine
oil filter.XXXXX X
Inspect the brake linings

Page 24 of 2585

CHRYSLER VOYAGER 2004 Service Manual Miles 93, 000 96, 000 99, 000 100, 000 102, 000 105, 000
(Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)
Change engine oil and engine
oil filter.XXX X X
Inspect the brake lini

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