CHRYSLER VOYAGER 2001 Service Manual

Fig. 2 FASTENER IDENTIFICATION
RGINTRODUCTION3a
FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH
4a INTRODUCTIONRG
FASTENER IDENTIFICATION (Continued)

FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RGINTRODUCTION5a

METRIC SYSTEM
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x
0.11298= Newton Meters
(N´m)N´m x 8.851 = in-lbs
ft-lbs x
1.3558= Newton Meters
(N´m)N´m x
0.7376= ft-lbs
Inches Hg (60É F) x 3.377 = Kilopascals (kPa) kPa x
0.2961= Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x
0.03937= Inches
Feet x
0.3048= Meters (M) M x 3.281 = Feet
Yards x
0.9144= Meters M x
1.0936= Yards
mph x
1.6093= Kilometers/Hr.
(Km/h)Km/h x
0.6214= mph
Feet/Sec x
0.3048= Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x
0.4470= Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr. (Km/h) x
0.27778= Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)
COMMON METRIC EQUIVALENTS
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters
1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer to the Metric Conversion Chart to convert
torque values listed in metric Newton- meters (N´m).
Also, use the chart to convert between millimeters
(mm) and inches (in.)
6a INTRODUCTIONRG

METRIC CONVERSION CHART
RGINTRODUCTION7a
METRIC SYSTEM (Continued)

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-tions Chart for torque references not listed in the
individual torque charts.
TORQUE SPECIFICATIONS
8a INTRODUCTIONRG

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel, near the left windshield
pillar (Fig. 5). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Built in the Graz Austria by DaimlerChrysler
2 Make C = Chrysler
3 Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags
8 = Multipurpose Pass. Vehicle With Side Air Bags
4 Gross Vehicle Weight
RatingG = 2268 - 2721 kg. (5001 - 6000 lbs.)
5 Car Line Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Right Hand Drive
I = Caravan FWD
6 Series 2 = Low Line
4 = High Line
5 = Premium
6 = Sport
7 = Special
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
8 Engine B = 2.4 L 4 cyl. MPI 16 - VALVE DOHC
R = 3.3 L 6 cyl. Gasoline MPI
M = 2.5 L 4 cyl. Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 1= 2001
11 Assembly Plant U = Graz Austria
12 through 17 Sequence Number A six digit number assigned by assembly plant.
Fig. 5 Vehicle Identification Number (VIN Plate)
1 - DEFROSTER OUTLET
2 - VIN #
3 - HEATED WINDSHIELD GRID
RGINTRODUCTION9a

VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 6) is located
on the rearward facing of the driver's door. This label
indicates date of manufacture (month and year),
Gross Vehicle Weight Rating (GVWR), Gross Axle
Weight Rating (GAWR) front, Gross Axle Weight Rat-
ing (GAWR) rear and the Vehicle Identification Num-
ber (VIN). The Month, Day and Hour (MDH) of
manufacture is also included.
When it is necessary to contact the manufacturer
regarding service or warranty, the information on the
Vehicle Safety Certification Label would be required.
E-MARK LABEL
DESCRIPTION
An E-mark Label (Fig. 7) is located on the rear
shut face of the driver's door. The label contains the
following information:
²Date of Manufacture
²Month-Day-Hour (MDH)
²Vehicle Identification Number (VIN)
²Country Codes
²Regulation Number
²Regulation Amendment Number
²Approval Number
VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot beremoved without defacing information and destroying
the label.
The label contains the vehicle's emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
MANUFACTURE PLATE
DESCRIPTION
The Manufacturer Plate (Fig. 8) is located in the
engine compartment on the passenger side strut
tower. The plate contains five lines of information:
²Vehicle Identification Number (VIN)
²Gross Vehicle Mass (GVM)
²Gross Train Mass (GTM)
²Gross Front Axle Rating (GFAR)
²Gross Rear Axle Rating (GRAR)Fig. 6 Vehicle Safety Certification Label
Fig. 7 E-Mark Label
1 - Country Code
2 - Regulation Number
3 - Approval Number
4 - Amendment Number
Fig. 8 Manufacturer Plate
10a INTRODUCTIONRG

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE
SPECIFICATIONS.........................1
INTERNATIONAL SYMBOLS
DESCRIPTION............................1
PARTS & LUBRICANT RECOMMENDATION
STANDARD PROCEDURE...................2
LUBRICANT CLASSIFICATIONS.............2
PARTS AND LUBRICANT
RECOMMENDATIONS....................2
FLUID TYPES
DESCRIPTION............................3
OPERATION.............................7
FLUID FILL/CHECK LOCATIONS
DESCRIPTION............................7MAINTENANCE SCHEDULES
DESCRIPTION............................7
HOISTING
STANDARD PROCEDURE..................16
HOISTING............................16
JUMP STARTING
STANDARD PROCEDURE..................16
JUMP STARTING.......................16
TOWING
STANDARD PROCEDURE..................17
TOWING RECOMMENDATIONS............17
LUBRICATION &
MAINTENANCE
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank 75 L (20 gal.)
Engine Oil* - 2.4L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8L 4.0 L (4.5 qts.)
Cooling System** - 2.4L 10.7 L (11.4 qts.)
Cooling System** -
3.3/3.8L without Rear
Heater12.6 L (13.4 qts.)
Cooling System** -
3.3/3.8L with Rear Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
31TH Overhaul Fill8.6 L (9.1 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 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.)
DESCRIPTION SPECIFICATION
AWD Rear Carrier 0.7 L (1.48 pts.)
*(includes oil filter)
**(includes heater and recovery/reserve bottle)
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 1).
Fig. 1 International Symbols
RSLUBRICATION & MAINTENANCE0-1

PARTS & LUBRICANT
RECOMMENDATION
STANDARD PROCEDURE - Classification of
Lubricants
Only lubricants that bear designations defined by
the following organization should be used to service a
DaimlerChrysler vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 2)
²National Lubricating Grease Institute (NLGI)
(Fig. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
²SAE 30 = single grade engine oil.
²SAE 10W-30 = multiple grade engine oil.Daim-
lerChrysler only recommends multiple grade engine
oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 2) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DaimlerChrysler.
Refer to Group 9, Engine for gasoline engine oil
specification.
FLEXIBLE FUEL ENGINE OIL ± 3.3L ENGINE
Engine Oil Selection for Operating on E-85
FuelIf vehicle operates on E-85 fuel either full or
part-time, use only MopartFlexible Fuel SAE 5W-30
engine oil or an equivalent that meets
DaimlerChrysler Standard MS-9214. Equivalent com-
mercial Flexible Fuel engine oils may be labeled asMulti-Fuel, Variable Fuel, Flexible Fuel, etc. These
engine oils are preferred for use in Flexible Fuel
engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3)on the label. At the bottom NLGI sym-
bol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
STANDARD PROCEDURE - PARTS AND
LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Motor
Corporation recommends that only Mopartbrand
parts, lubricants and chemicals be used. Mopar pro-
vides the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
ENGINE COOLANT
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. (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCERS