CHRYSLER VOYAGER 1996 Service Manual

CHRYSLER
INTERNATIONAL
SERVICE MANUAL
1998
CHRYSLER VOYAGER
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANICAL,
PHOTOCOPYING, RECORDING, OR OTHERWISE,
WITHOUT THE PRIOR WRITTEN PERMISSION
OF CHRYSLER INTERNATIONAL.
Chrysler International reserves the right to make changes in design or to
make additions to or improvements in its products without imposing any obli-
gations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1976 Chrysler Corporation

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner 's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
Chrysler International reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.

GROUP TAB LOCATOR
Introduction
0Lubrication and Maintenance
2Suspension
5Brakes
6Clutch
7Cooling System
8ABattery
8BStarting System
8EInstrument Panel and Systems
8HVehicle Speed Control System
8KWiper and Washer Systems
8LLamps
8QVehicle Theft/Security Systems
8UChime Warning/Reminder System
8WWiring Diagrams
9Engine
13Frame and Bumpers
14Fuel SystemÐ2.5L Diesel Engine/2.0L Gas Engine
19Steering
21AÐ598 Manual Transaxle
23Body
24Heating and Air Conditioning
25Emission Control System

INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE...................... 1
FASTENER IDENTIFICATION................ 4
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS..................... 4METRIC SYSTEM........................ 7
TORQUE REFERENCES................... 7
VEHICLE IDENTIFICATION NUMBER.......... 1
VEHICLE SAFETY CERTIFICATION LABEL..... 1
VIN CHECK DIGIT........................ 1
GENERAL INFORMATION
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 1) is located
on the rear shut face 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 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.
VEHICLE IDENTIFICATION NUMBER
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. 2). 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.
VIN CHECK DIGIT
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.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Plate (Fig. 3) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.Fig. 1 Vehicle Safety Certification Label
Fig. 2 Vehicle Identification Number (VIN Plate)
NSINTRODUCTION 1

BODY CODE PLATE ± LINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13 THROUGH 17
Open space
DIGITS 18 AND 19
Vehicle Shell Line
²NSDIGIT 20
Carline
FWD
²H = Plymouth
²K = Dodge
²S = Chrysler
AW D
²C = Chrysler
²D = Dodge
²P = Plymouth
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 = Canada
2 Make B = Dodge
C = Chrysler
P = Plymouth
3 Vehicle Type 4 = Multipurpose Pass. Vehicle
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg (5001 - 6000 lbs)
5 Car Line P = Chrysler, Town & Country
P = Dodge, Caravan/Grand Caravan
P = Plymouth, Voyager/Grand Voyager
T = AWD Chrysler, Town & Country
T = AWD Dodge, Grand Caravan
T = AWD Plymouth, Grand Voyager
6 Series 2 = FWD Caravan/Grand Caravan, Voyager/
Grand Voyager
4 = Caravan SE/Grand Caravan SE, Voyager
SE/Grand Voyager SE
5 = Caravan LE or ES/Grand Caravan LE or ES,
Voyager LE/Grand Voyager LE, Town & Country
LX
6 = Town & Country LXI
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
8 Engine B = 2.4 L 4 cyl. MPI 16-VALVE DOHC
3 = 3.0 L 6 cyl. gas MPI
R = 3.3L 6 cyl. gas MPI
L = 3.8 L 6 cyl. gas MPI
9 Check Digit See explanation in this section.
10 Model Year V = 1997
11 Assembly Plant B = St. Louis South
R = Windsor
12 thru 17 Sequence Number 6 digit number assigned by assembly plant.
2 INTRODUCTIONNS
GENERAL INFORMATION (Continued)

DIGIT 21
Price Class
²H = Highline
²L = Lowline
²P = Premium
²S = Luxury
DIGITS 22 AND 23
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Primary paint
See Group 23, Body for color codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Paint
DIGIT 14
Open SpaceDIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²EDZ = 2.4L 4 cyl. DOHC Gasoline
²EFA = 3.0L 6 cyl. Gasoline
²EGA = 3.3L 6 cyl. Gasoline
²EGH = 3.8L 6 cyl. Gasoline
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGB = 31TH 3-Speed Automatic Transaxle
²DGL = 41TE 4-speed Electronic Automatic Tran-
saxle
²DGM = 31TH 3-Speed Automatic Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
Fig. 3 Body Code Plate
NSINTRODUCTION 3
GENERAL INFORMATION (Continued)

INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS INTERNATIONAL VEHICLE CONTROL
AND DISPLAY SYMBOLS
The graphic symbols illustrated in the following
chart (Fig. 4) are used to identify various instrument
controls. The symbols correspond to the controls and
displays that are located on the instrument panel.
FASTENER IDENTIFICATION
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metric bolt/nut threads are not the same.
The difference is described in the Thread Notation
chart (Fig. 5).
GRADE/CLASS IDENTIFICATION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actualbolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 12.9. The metric strength
class identification number is imprinted on the head of
the bolt. The higher the class number, the greater the
bolt strength. Some metric nuts are imprinted with a
single-digit strength class on the nut face. Refer to the
Fastener Identification and Fastener Strength Charts.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
Fig. 4
Fig. 5 Thread NotationÐSAE and Metric
4 INTRODUCTIONNS
GENERAL INFORMATION (Continued)

FASTENER IDENTIFICATION
NSINTRODUCTION 5
GENERAL INFORMATION (Continued)

FASTENER STRENGTH
6 INTRODUCTIONNS
GENERAL INFORMATION (Continued)

METRIC SYSTEM
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 metric fasteners (nuts, bolts,
etc.) for reassembly. If the fastener is not salvage-
able, a fastener of equivalent specification should be
used.
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million (Fig.
6).
The following chart will assist in converting metric
units to equivalent English and SAE units, or vise
versa.
Refer to the 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.)
TORQUE REFERENCES
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-
cations Chart for torque references not listed in the
individual torque charts.
Fig. 6 Metric Prefixes
CONVERSION FORMULAS AND EQUIVALENT VALUES
NSINTRODUCTION 7
GENERAL INFORMATION (Continued)