2005 CHRYSLER VOYAGER oil

As disc brake shoe linings wear, master cylinder
reservoir brake fluid level will drop. Adjust as neces-
sary. Fluid level should always be checked after
replacing shoes.
OPERATION - DISC BRAKES (REAR)
The rear disc brakes operate similarly to front disc
brakes, however, there are some features that require
different service procedures.
DIAGNOSIS AND TESTING - DRUM BRAKE
AUTOMATIC ADJUSTER
The rear drum brakes on this vehicle automatically
adjust when required during the normal operation of
the vehicle every time the brakes are applied. Use
the following procedure to test the operation of the
automatic adjuster.
Place the vehicle on a hoist with a helper in the
driver's seat to apply the brakes. Remove the access
plug from the adjustment hole in each brake support
plate to provide visual access of the brake adjuster
star wheel.
To eliminate the condition where maximum adjust-
ment of the rear brake shoes does not allow the auto-
matic adjuster to operate when tested, back the star
wheel off approximately 30 notches. It will be neces-
sary to hold the adjuster lever away from the star
wheel to permit this adjustment.
Have the helper apply the brakes. Upon applica-
tion of the brake pedal, the adjuster lever should
move down, turning the adjuster star wheel. Thus, a
definite rotation of the adjuster star wheel can be
observed if the automatic adjuster is working prop-
erly. If one or more adjusters do not function prop-
erly, the respective drum must be removed for
adjuster servicing.
BRAKE LINES
DESCRIPTION - BRAKE TUBES AND HOSES
The brake tubes are steel with a corrosion-resis-
tant nylon coating applied to the external surfaces.
The flex hoses are made of reinforced rubber with fit-
tings at each end.
The primary and secondary brake tubes leading
from the master cylinder to the ABS ICU Hydraulic
Control Unit (HCU) or the non-ABS junction block
have a special flexible section. This flexible section is
required due to cradle movement while the vehicle is
in motion (The ICU and non-ABS junction block are
mounted to the cradle).If replacement of these
lines is necessary, only the original factory
brake line containing the flexible section must
be used.
OPERATION - BRAKE TUBES AND HOSES
The purpose of the chassis brake tubes and flex
hoses is to transfer the pressurized brake fluid devel-
oped by the master cylinder to the wheel brakes of
the vehicle. The flex hoses are made of rubber to
allow for the movement of the vehicle's suspension.
INSPECTION - BRAKE TUBES AND HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is
serviced and every 7,500 miles or 12 months, which-
ever comes first (every engine oil change). Inspect
hydraulic brake hoses for surface cracking, scuffing,
or worn spots. If the fabric casing of the rubber hose
becomes exposed due to cracks or abrasions in the
rubber hose cover, the hose should be replaced imme-
diately. Eventual deterioration of the hose can take
place with possible burst failure. Faulty installation
can cause twisting, resulting in wheel, tire, or chassis
interference.
The brake tubing should be inspected periodically
for evidence of physical damage or contact with mov-
ing or hot components.
The flexible brake tube sections used on this vehi-
cle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit
connections must also be inspected. This flexible tub-
ing must be inspected for kinks, fraying and contact
with other components or with the body of the vehi-
cle.
Fig. 10 Caliper Piston Seal Function For Automatic
Adjustment
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
5 - 14 BRAKES - BASERS
HYDRAULIC/MECHANICAL (Continued)

master cylinder reservoir from completely draining
out.
(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws.
(5) Remove the piston dust boot from the caliper
and discard.
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 32). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.CLEANING - CALIPER
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
To clean or flush the internal passages of the brake
caliper, use fresh brake fluid or MopartNon-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
²Brake fluid leaks in and around boot area and
inboard lining
²Ruptures, brittleness or damage to the piston
dust boot
²Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
ASSEMBLY
ASSEMBLY - CALIPER GUIDE PIN BUSHINGS
(CONTINENTAL TEVES BRAKES)
(1) Fold the guide pin bushing in half lengthwise.
NOTE: To avoid damage to the bushing, do not use
a sharp object to install the guide pin bushing.
(2) Insert the folded bushing into the caliper
mounting boss using your fingers from the rear of
the caliper.
Fig. 32 Removing Piston Seal
1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL
RSBRAKES - BASE5-25
DISC BRAKE CALIPER - FRONT (Continued)

(3) Disconnect the brake fluid flex hose from the
caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamp-
ing caliper in vise. Excessive vise pressure will
cause bore distortion.
(4) Mount the caliper in a vise equipped with pro-
tective jaws.
(5) Remove the piston dust boot from the caliper
and discard.
NOTE: Do not use a screw driver or other metal tool
for seal removal. Using such tools can scratch the
bore or leave burrs on the seal groove edges.
(6) Using a soft tool such as a plastic trim stick,
work the piston seal out of its groove in caliper pis-
ton bore (Fig. 38). Discard the old seal.
(7) Clean the piston bore and drilled passage ways
using alcohol or a suitable solvent. Wipe it dry using
only a lint-free cloth.
(8) Inspect the piston bore for scoring or pitting.
Bores that show light scratches or corrosion can usu-
ally be cleared of the light scratches or corrosion
using crocus cloth.CLEANING - CALIPER
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
AFTERMARKET BRAKE LININGS. BREATHING
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT SAND OR GRIND BRAKE LINING
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
DAMPENING THE BRAKE COMPONENTS WITH A
FINE MIST OF WATER, THEN WIPING THE BRAKE
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
To clean or flush the internal passages of the brake
caliper, use fresh brake fluid or MopartNon-Chlori-
nated Brake Parts Cleaner. Never use gasoline, ker-
osene, alcohol, oil, transmission fluid or any fluid
containing mineral oil to clean the caliper. These flu-
ids will damage rubber cups and seals.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
²Brake fluid leaks in and around boot area and
inboard lining
²Ruptures, brittleness or damage to the piston
dust boot
²Damaged, dry or brittle guide pin dust boots
If caliper fails inspection, disassemble and recondi-
tion caliper, replacing the seals and dust boots.
Fig. 38 Removing Piston Seal
1 - PLASTIC TRIM STICK
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL
RSBRAKES - BASE5-29
DISC BRAKE CALIPER - REAR (Continued)

FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brake hydraulic unit and all hydraulic fluid
hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL CHECKING
Check master cylinder reservoir fluid level a mini-
mum of twice annually.
Fluid reservoirs are marked with the words FULL
and ADD to indicate proper brake fluid fill level of
the master cylinder.
If necessary, add brake fluid to bring the level to
the bottom of the FULL mark on the side of the mas-
ter cylinder fluid reservoir.
Use only Mopartbrake fluid or equivalent from a
sealed container. Brake fluid must conform to DOT 3
specifications (DOT 4 or DOT 4+ are acceptable).
DO NOTuse brake fluid with a lower boiling
point, as brake failure could result during prolonged
hard braking.
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.
44).
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 block
mounts 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.
RSBRAKES - BASE5-33

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM........1
DESCRIPTION - HOSE CLAMPS...........1
OPERATION
OPERATION - COOLING SYSTEM.........2
OPERATION - HOSE CLAMPS............2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TEST....................2
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK.................3
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION....................4
DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION..................4
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING
SYSTEM DRAINING....................4STANDARD PROCEDURE - COOLING
SYSTEM FILLING......................4
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT.................4
STANDARD PROCEDURE - COOLANT
LEVEL CHECK........................4
SPECIFICATIONS
ACCESSORY DRIVE BELT TENSION.......5
TORQUE.............................5
SPECIAL TOOLS
COOLING SYSTEM.....................6
ACCESSORY DRIVE.......................7
ENGINE...............................13
TRANSMISSION.........................38
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
The cooling system components consist of a radia-
tor, electric fan motors, shroud, pressure cap, thermo-
stat, transmission oil cooler, water pump, hoses,
clamps, coolant, and a coolant reserve system to com-
plete the circuit.
DESCRIPTION - HOSE CLAMPS
The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,
replace with the original Mopartequipment spring
type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1).
Fig. 1 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
RSCOOLING7-1

OPERATION
OPERATION - COOLING SYSTEM
The engine cooling systems primary purpose is to
maintain engine temperature in a range that will
provide satisfactory engine performance and emission
levels under all expected driving conditions. It also
provides hot water (coolant) for heater performance
and cooling for automatic transmission oil. It does
this by transferring heat from engine metal to cool-
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.
²When engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²When engine is warm: thermostat is open, cool-
ing system has bypass flow and coolant flow through
radiator.
Coolant flow circuits for the 2.4L and 3.3/3.8L
engines are shown in (Fig. 2).
OPERATION - HOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 3) to compress the
hose clamp.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAK TEST
WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
Fig. 2 Cooling System Flow
1 - HEATER - REAR (3.3/3.8L OPTIONAL EQUIPMENT) 6 - WATER PUMP
2 - HEATER - FRONT 7 - RADIATOR
3 - ENGINE 8 - COOLANT RECOVERY/RESERVE CONTAINER
4 - THERMOSTAT 9 - COOLANT FLOW - PRESSURE CAP VACUUM
5 - ENGINE OIL COOLER (3.3/3.8L OPTIONAL EQUIPMENT) 10 - COOLANT FLOW - PRESSURE CAP RELIEF
7 - 2 COOLINGRS
COOLING (Continued)

With engine not running, remove radiator pressure
cap and wipe the radiator filler neck sealing seat
clean. The radiator should be full.
Attach the Cooling System Tester 7700 or equiva-
lent to the radiator, as shown in (Fig. 4) and apply
104 kPa (15 psi) pressure. If the pressure drops more
than 13.8 kPa (2 psi) in 2 minutes, inspect all points
for external leaks.
All radiator and heater hoses should be shaken
while at 104 kPa (15 psi), since some leaks occur only
while driving due to engine movement.If there are no external leaks, after the gauge dial
shows a drop in pressure, detach the tester. Start
engine and run until the thermostat opens, allowing
the coolant to expand. Reattach the cooling system
tester. If the needle on the dial fluctuates it indicates
a combustion leak, usually a head gasket leak.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL
BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP,
BY CONTINUOUS ENGINE OPERATION, MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, raise
the engine rpm a few times. If an abnormal amount
of coolant or steam emits from the tailpipe, it may
indicate a coolant leak caused by a faulty head gas-
ket, cracked engine block, or cracked cylinder head.
There may be internal leaks that can be deter-
mined by removing the oil dipstick. If water globules
appear intermixed with the oil it will indicate an
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
DIAGNOSIS AND TESTING - COOLING SYSTEM
FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use one of the following proce-
dures:
PREFERRED METHOD
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP OR ANY HOSE WITH THE
SYSTEM HOT AND UNDER PRESSURE BECAUSE
SERIOUS BURNS FROM COOLANT CAN OCCUR.
²Remove pressure cap when engine is cold.
Remove small amount of coolant. Idle engine until
thermostat opens. You should observe coolant flow
while looking down the filler neck. Once flow is
detected install the pressure cap. Replace removed
coolant into coolant recovery container.
ALTERNATIVE METHOD
²If engine is cold, idle engine until normal oper-
ating temperature is reached. Feel the upper radiator
hose. If it is hot, coolant is circulating.
Fig. 3 Hose Clamp Tool
1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
Fig. 4 Pressure Testing
RSCOOLING7-3
COOLING (Continued)

SPECIFICATIONS
ACCESSORY DRIVE BELT TENSION
ACCESSORY
DRIVE BELTTENSION
2.4L ENGINE
Air Conditioning
Compressor/
GeneratorDynamic Tensioner
Power
SteeringNew
Belt534 - 756 N
178 - 212 Hz
(120 - 170
lbs.)
Used
Belt*356 - 534 N
145 - 178 Hz
(80 - 120 lbs)
*Belt is considered used after 15 minutes of run-in
time
3.3/3.8L ENGINES
Air Conditioning
CompressorDynamic
Tensioner
Generator/Water
Pump/Power
Steering
TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Bolt, Accessory Drive Belt
Tensioner Assembly (3.3/3.8L)28 - 250
Engine Coolant Temperature
Sensor7-60
Bolt, Generator & A/C Compressor
Drive Belt Tensioner Assembly
(2.4L)54 40 -
Bolts, Coolant Outlet Connector/
Thermostat Housing28 - 250
Bolts, Water Pump 12 - 105
Bolts , Water Pump Inlet Tube
(2.4L)12 - 105
Bolts, Water Pump Inlet Tube
(3.3/3.8L)28 - 250
Bolts, Water Pump Pulley (3.3/3.8L) 28 - 250
Screws, Radiator to A/C Condenser 5 - 45
Screws, Radiator Fan 5 - 45
Nuts, Radiator Mounting (Upper
Bracket)12 - 105
Fig. 5 Cooling System Service Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
RSCOOLING7-5
COOLING (Continued)