2004 CHRYSLER VOYAGER Temperature

sensor airbag clutch spark plugs replace jump start warning light

Page 6 of 2585

CHRYSLER VOYAGER 2004 Service Manual FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque specifications references in
thi

Page 15 of 2585

CHRYSLER VOYAGER 2004 Service Manual ²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Certified (GF-3).

²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Certified (GF-3).
Mopartprovides engine oils, meeting Material Stan-
dard MS-6395, that meet or exceed this requirement.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 2).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the front
label of engine oil plastic bottles and the top of
engine oil cans (Fig. 3).
This symbol means that the oil has been certified
by the American Petroleum Institute (API). Diamler-
Chrysler only recommends API Certified (GF-3)
engine oils that meet the requirements of Material
Standard MS-6395. Use Mopartor an equivalent oil
meeting the specification MS-6395.
SYNTHETIC ENGINE OILS
There are a number of engine oils being promoted
as either synthetic or semi-synthetic. If you chose touse such a product, useonlythose oils that meet the
American Petroleum Institute (API) and SAE viscos-
ity standard. Follow the service schedule that
describes your driving type.
ENGINE OIL ADDITIVES/SUPPLEMENTS
The manufacturerdoes not recommendthe addi-
tion of any engine oil additives/supplements to the
specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil perfor-
mance. Engine oil additives/supplements should not
be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and
can degrade emission components. Additives can con-
tain undesirable materials that harm the long term
durability of engines by:
²Doubling the level of Phosphorus in the engine
oil. The ILSAC (International Lubricant Standard
Approval Committee) GF-2 and GF-3 standards
require that engine oil contain no more than 0.10%
Phosphorus to protect the vehicles emissions perfor-
mance. Addition of engine oil additives/supplements
can poison, from the added sulfur and phosphorus,
catalysts and hinder efforts to guarantee emissions
performance to 80,000 miles.
²Altering the viscosity characteristics of the
engine oil so that it no longer meets the require-
ments of the specified viscosity grade.
²Creating potential for an undesirable additive
compatibility interaction in the engine crankcase.
Generally it is not desirable to mix additive packages
from different suppliers in the crankcase; there have
been reports of low temperature engine failures
caused by additive package incompatibility with such
mixtures.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY
Fig. 3 API SYMBOL
0 - 2 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

Page 16 of 2585

CHRYSLER VOYAGER 2004 Service Manual LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage an

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
letter ªGº. Chassis lubricant is identified by the letter
ªLº. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
The information in this section is for Flexible Fuel
Vehicles (FFV) only. These vehicles can be identified
by the unique Fuel Filler Door Label that states
Ethanol (E-85) or Unleaded Gasoline Only. This sec-
tion only covers those subjects that are unique to
these vehicles. Please refer to the other sections of
this manual for information on features that are
common between Flexible Fuel and gasoline only
powered vehicles.
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel etha-
nol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
cle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-3
FLUID TYPES (Continued)

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 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 28 of 2585

CHRYSLER VOYAGER 2004 Service Manual * 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 s

* 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.
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.
DESCRIPTION - 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.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
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(.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 manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Rotate the tires at each oil change interval
shown on Schedule ªAº 12 000 km (7,500 miles) or
every other interval shown on Schedule ªBº 10 000
km (6,000 miles).
RSLUBRICATION & MAINTENANCE0-15
MAINTENANCE SCHEDULES (Continued)

Page 31 of 2585

CHRYSLER VOYAGER 2004 Service Manual SCHEDULE B - EXPORT ONLY
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 96 000 km (60

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