weight CHRYSLER VOYAGER 1996 Owner's Manual

REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 47).
(4) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate rear of caliper up from
the adapter. Then pull the front of the caliper and
the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 48).
(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
49).
INSTALL
NOTE: Step 1 below is only required when install-
ing the disc brake caliper after new brake shoes
have been installed.
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both adapter abutments with a lib-
eral amount of MopartMultipurpose Lubricant, or
equivalent.
(3) If removed, install the rear rotor on the hub,
making sure it is squarely seated on the face of the
hub.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
(4) Carefully lower caliper and brake shoes over
rotor and onto the adapter using the reverse proce-
dure for removal (Fig. 48).
CAUTION: When installing guide pin bolts extreme
caution should be taken not to crossthread the cal-
iper guide pin bolts.
(5) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 22 N´m (192 in. lbs.).
(6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud nuts in
proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to
the full specified torque of 129 N´m (95 ft. lbs.).
(8) Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake
pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
Fig. 47 Removing Caliper Guide Pin Bolts
Fig. 48 Removing / Installing Caliper
Fig. 49 Correctly Supported Caliper
NSBRAKES 5 - 29
REMOVAL AND INSTALLATION (Continued)

REAR DISC BRAKE SHOES
WARNING: ALTHOUGH FACTORY INSTALLED
BRAKELININGS ARE MADE FROM ASBESTOSFREE MATERIALS, SOME AFTER MARKET BRAKE-
LINING MAY CONTAIN ASBESTOS. THIS SHOULD
BE TAKEN INTO ACCOUNT WHEN SERVICING A
VEHICLE'S BRAKE SYSTEM, WHEN AFTERMARKET
BRAKELININGS MAY HAVE BEEN INSTALLED ON
THE VEHICLE. ALWAYS WEAR A RESPIRATOR
WHEN CLEANING BRAKE COMPONENTS AS
ASBESTOS CAN CAUSE SERIOUS BODILY HARM
SUCH AS ASBESTOSIS AND OR CANCER. NEVER
CLEAN BRAKE COMPONENTS BY USING COM-
PRESSED AIR, USE ONLY A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR THE REMOVAL OF
BRAKE DUST. IF A VACUUM CLEANER IS NOT
AVAILABLE, CLEAN BRAKE PARTS USING ONLY
WATER DAMPENED SHOP TOWELS. DO NOT CRE-
ATE BRAKELINING DUST BY SANDING BRAKE LIN-
INGS WHEN SERVICING A VEHICLE. DISPOSE OF
ALL DUST AND DIRT SUSPECTED OF CONTAINING
ASBESTOS FIBERS USING ONLY SEALED AIR-
TIGHT BAGS OR CONTAINERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
PROTECTION AGENCY (EPA), FOR HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBES-
TOS.
During service procedures, grease or any other for-
eign material must be kept off brake shoe assem-
blies, and braking surfaces of brake drum and
external surfaces of hub/bearing assembly.
Handling of the braking disc and caliper is to be
done in such a way as to avoid deformation of the
disc and scratching or nicking of brake linings.
If inspection reveals that the square sectioned cal-
iper piston seal is worn or damaged, itMUSTbe
replaced immediately.
During removal and installation of a wheel and
tire assembly, use care not to strike the caliper.
REMOVE
(1) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in the Lubrication and Mainte-
nance section of this manual.
(2) Remove rear wheel and tire assemblies from
vehicle.
(3) Remove the caliper to adapter guide pin bolts
(Fig. 55).
(4) Remove rear caliper from adapter using the fol-
lowing procedure. First rotate rear of caliper up from
the adapter. Then pull the front of the caliper and
the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 56).
(5) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
57).
Fig. 52 Front Brake Pad Assembly Identification
Fig. 53 Installing Inboard Brake Pad Assembly
Fig. 54 Installing Outboard Brake Shoe Assembly
NSBRAKES 5 - 31
REMOVAL AND INSTALLATION (Continued)

from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 92).(12) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
93).
(13) Remove the rotor from the hub/bearing.
Fig. 87 Spring Washer
Fig. 88 Hub Nut And Washer
Fig. 89 Driveshaft Attachment To Driveline Module
Fig. 90 Wheel Speed Sensor
Fig. 91 Caliper Guide Pin Bolts
Fig. 92 Removing / Installing Caliper
5 - 42 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(23) Install the negative (ground) cable on the bat-
tery.
(24) Cycle the park brake pedal one time. This will
seat the park brake cables and will allow the auto-
matic self adjuster to properly tension the park brake
cables.
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
On this vehicle, the park brake shoes are removed
from the disc brake adapter with the disc brake
adapter removed from the vehicle.
REMOVE
(1) Set the parking brake.The parking brake is
set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut.
(2) Raise vehicle. Vehicle is to be raised and sup-
ported on jackstands or on a frame contact type
hoist. See Hoisting in the Lubrication And Mainte-
nance section of this service manual.
(3) Remove the wheel/tire.
(4) Remove the cotter pin and nut retainer (Fig.
139) from the stub shaft of the outer C/V joint.
(5) Remove the spring washer (Fig. 140) from the
stub shaft of the outer C/V joint.
(6) Remove the hub nut and washer (Fig. 141)
from the stub shaft of the outer C/V joint.
(7) Release the parking brake.
(8) Create slack in the rear park brake cables by
locking the out the automatic adjuster as described.
Grasp the exposed section of front park brake cable
and pull downward on it. Then install a pair of lock-
ing pliers on the front park brake cable just rearward
of the second body outrigger bracket (Fig. 142).
(9) Remove the disc brake caliper to adapter guide
pin bolts (Fig. 143).
(10) Remove rear caliper from adapter using the
following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliperand the outboard brake shoe anti-rattle clip out from
under the front abutment on the adapter (Fig. 144).
(11) Support caliper to prevent the weight of the
caliper from damaging the flexible brake hose (Fig.
Fig. 139 Cotter Pin And Nut Retainer
Fig. 140 Spring Washer
Fig. 141 Hub Nut And Washer
Fig. 142 Locking Out Automatic Adjuster
5 - 60 BRAKESNS
REMOVAL AND INSTALLATION (Continued)

(13) Lower the vehicle to the ground.Be sure
that the suspension is supporting the full
weight of the vehicle.
(14) Tighten the spring to front hanger pivot bolts
to a torque of 156 N´m (115 ft. lbs.).
(15) Tighten the shock absorber mounting bolts to
a torque of 101 N´m (75 ft. lbs.).
(16) Tighten the track bar mounting bolt to a
torque of 95 N´m (70 ft. lbs.).
(17) Road test vehicle to ensure that the prema-
ture rear wheel lockup condition has been corrected.
SPECIFICATIONS
BRAKE FLUID
The brake fluid used in this vehicle must conform
to DOT 3 specifications and SAE J1703 standards.No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
only Mopar brake fluid or an 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 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 ect.
VEHICLE BRAKE SYSTEM COMPONENT SPECIFICATIONS
Brake System Component Specifications
5 - 82 BRAKESNS
ADJUSTMENTS (Continued)

ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE
This ABS System represents the current state-of-
the-art in vehicle braking systems and offers the
driver increased safety and control during braking.
This is accomplished by a sophisticated system of
electrical and hydraulic components. As a result,
there are a few performance characteristics that may
at first seem different but should be considered nor-
mal. These characteristics are discussed below.
NORMAL BRAKING SYSTEM FUNCTION
Under normal braking conditions, the ABS System
functions the same as a standard brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS SYSTEM OPERATION
If a wheel locking tendency is detected during a
brake application, the brake system will enter the
ABS mode. During ABS braking, hydraulic pressure
in the four wheel circuits is modulated to prevent
any wheel from locking. Each wheel circuit is
designed with a set of electric solenoids to allow mod-
ulation, although for vehicle stability, both rear
wheel solenoids receive the same electrical signal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into four control channels.
During antilock operation of the vehicle's brake sys-
tem the front wheels are controlled independently
and are on two separate control channels and the
rear wheels of the vehicle are controlled together.
The system can build and release pressure at each
wheel, depending on signals generated by the wheel
speed sensors (WSS) at each wheel and received at
the Controller Antilock Brake (CAB).
ABS operation is available at all vehicle speeds
above 3 to 5 mph. Wheel lockup may be perceived at
the very end of an ABS stop and is considered nor-
mal.
VEHICLE HANDLING PERFORMANCE DURING
ABS BRAKING
It is important to remember that an antilock brake
system does not shorten a vehicle's stopping distance
under all driving conditions, but does provide
improved control of the vehicle while stopping. Vehi-
cle stopping distance is still dependent on vehicle
speed, weight, tires, road surfaces and other factors.
Though ABS provides the driver with some steer-
ing control during hard braking, there are conditions
however, where the system does not provide any ben-
efit. In particular, hydroplaning is still possible when
the tires ride on a film of water. This results in the
vehicles tires leaving the road surface rendering the
vehicle virtually uncontrollable. In addition, extremesteering maneuvers at high speed or high speed cor-
nering beyond the limits of tire adhesion to the road
surface may cause vehicle skidding, independent of
vehicle braking. For this reason, the ABS system is
termed Antilock instead of Anti-Skid.
NOISE AND BRAKE PEDAL FEEL
During ABS braking, some brake pedal movement
may be felt. In addition, ABS braking will create
ticking, popping and/or groaning noises heard by the
driver. This is normal due to pressurized fluid being
transferred between the master cylinder and the
brakes. If ABS operation occurs during hard braking,
some pulsation may be felt in the vehicle body due to
fore and aft movement of the suspension as brake
pressures are modulated.
At the end of an ABS stop, ABS will be turned off
when the vehicle is slowed to a speed of 3±4 mph.
There may be a slight brake pedal drop anytime that
the ABS is deactivated, such as at the end of the stop
when the vehicle speed is less then 3 mph or during
an ABS stop where ABS is no longer required. These
conditions will exist when a vehicle is being stopped
on a road surface with patches of ice, loose gravel or
sand on it. Also stopping a vehicle on a bumpy road
surface will activate ABS because of the wheel hop
caused by the bumps.
TIRE NOISE AND MARKS
Although the ABS system prevents complete wheel
lock-up, some wheel slip is desired in order to
achieve optimum braking performance. Wheel slip is
defined as follows, 0 percent slip means the wheel is
rolling freely and 100 percent slip means the wheel is
fully locked. During brake pressure modulation,
wheel slip is allowed to reach up to 25 to30%. This
means that the wheel rolling velocity is 25 to 30%
less than that of a free rolling wheel at a given vehi-
cle speed. This slip may result in some tire chirping,
depending on the road surface. This sound should not
be interpreted as total wheel lock-up.
Complete wheel lock up normally leaves black tire
marks on dry pavement. The ABS System will not
leave dark black tire marks since the wheel never
reaches a fully locked condition. Tire marks may
however be noticeable as light patched marks.
START UP CYCLE
When the ignition is turned on, a popping sound
and a slight brake pedal movement may be noticed.
Additionally, when the vehicle is first driven off a
humming may be heard and/or felt by the driver at
approximately 20 to 40 kph (12 to 25 mph). The ABS
warning lamp will also be on for up to 5 seconds
after the ignition is turned on. All of these conditions
are a normal function of ABS as the system is per-
forming a diagnosis check.
5 - 86 BRAKESNS
DESCRIPTION AND OPERATION (Continued)

2.4L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
CAMSHAFT POSITION SENSOR............ 17
CRANKSHAFT POSITION SENSOR.......... 16
FIRING ORDERÐ2.4L.................... 16
INTAKE AIR TEMPERATURE SENSORÐ2.4L . . . 17
REMOVAL AND INSTALLATION
CAMSHAFT POSITION SENSOR............ 19
CRANKSHAFT POSITION SENSOR.......... 19
ENGINE COOLANT TEMPERATURE SENSORÐ
2.4L................................. 20
IGNITION COILÐ2.4L..................... 18
INTAKE AIR TEMPERATURE SENSORÐ2.4L . . . 21KNOCK SENSORÐ2.4L................... 21
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐ2.4/3.3/3.8L.................. 20
SPARK PLUG CABLE SERVICEÐ2.4L........ 18
SPARK PLUG SERVICE................... 18
THROTTLE POSITION SENSOR............ 20
SPECIFICATIONS
IGNITION COIL......................... 22
SPARK PLUG CABLE RESISTANCEÐ2.4L..... 22
SPARK PLUG........................... 22
TORQUE.............................. 22
DESCRIPTION AND OPERATION
FIRING ORDERÐ2.4L
CRANKSHAFT POSITION SENSOR
The PCM determines what cylinder to fire from the
crankshaft position sensor input and the camshaft
position sensor input. The second crankshaft counter-
weight has machined into it two sets of four timing
reference notches and a 60 degree signature notch
(Fig. 1). From the crankshaft position sensor input
the PCM determines engine speed and crankshaft
angle (position).The notches generate pulses from high to low in
the crankshaft position sensor output voltage. When
a metal portion of the counterweight aligns with the
crankshaft position sensor, the sensor output voltage
goes low (less than 0.3 volts). When a notch aligns
with the sensor, voltage switches high (5.0 volts). As
a group of notches pass under the sensor, the output
voltage switches from low (metal) to high (notch)
then back to low.
If available, an oscilloscope can display the square
wave patterns of each voltage pulse. From the width
of the output voltage pulses, the PCM calculates
engine speed. The width of the pulses represent the
amount of time the output voltage stays high before
switching back to low. The period of time the sensor
output voltage stays high before switching back to
low is referred to as pulse width. The faster the
FIRING ORDERÐ2.4L
Fig. 1 Timing Reference Notches
8D - 16 IGNITION SYSTEMNS

HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT................... 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION....... 5ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN.................... 5
GENERAL INFORMATION
HEADLAMP ALIGNMENT
The headlamps are equipped with a bubble level
for up/down headlamp alignment. The bubble is cen-
tered with the vehicle on a level surface. A horizontal
gauge and magnifying window is located next to the
bubble level for left/right alignment (Fig. 1). Aim on
every headlamp assembly is calibrated at the head-
lamp manufacturer. At the vehicle assembly plant,
the vertical aim is set by centering the bubble with
the vehicle on a level surface. Horizontal aim is con-
trolled by the mounting pads on each headlamp
mounting panel.
When the vehicle is to be used with a heavy load,
the bubble level can be used to compensate for the
altered ride height.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 2).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
Fig. 1 Magnifying Window and Bubble Level
NSLAMPS 8L - 5

HEADLAMP ALIGNMENT
INDEX
page page
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION...... 5ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN.................. 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Verify that the headlamp leveling switch is in
the ª0º position.
(3) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(4) Verify proper tire inflation.
(5) Clean headlamp lenses.
(6) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 1).
(2) Place 75 kg in the driver's seat to simulate the
ride height of the vehicle when driven.
(3) If necessary, tape a line on the floor 10 meters
(32.8 ft) away from and parallel to the wall.
(4) From the floor up 1.27 meters (5 ft), tape a line
on the wall at the centerline of the vehicle. Sight
along the centerline of the vehicle (from rear of vehi-
cle forward) to verify accuracy of the line placement.
NS/GSLAMPS 8L - 5

If motor grunts and does not move, verify that reg-
ulator is not binding.
WIRING VOLTAGE TEST
The following wiring test determines whether or
not voltage is continuous through the body harness
to switch.
(1) Remove the master power window switch and
bezel assembly from the driver door. Refer to Group
23, Body for proper procedures.
(2) Disconnect wire connector from back of power
window switch.
(3) Switch ignition ON position.
(4) Connect the clip end of a 12 volt test light to
Pin 13 in door harness connector at the window
switch. Touch the test light probe to Pin 9 and then
to Pin 11.
²If the test light illuminates, the wiring circuit
between the battery and switch is OK.
²If light does not illuminate, check the 40 amp
fuse in the Power Distribution Center or for a broken
wire.
²The power window motors are protected with
Positive Temperature Coefficient (PTC) device that
prevents motor burn out. Check Junction Block.
²Refer to Group 8W, Wiring Diagrams for circuit
information and component locations.
REMOVAL AND INSTALLATION
POWER VENT WINDOW MOTOR
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove D-pillar trim panel.
(3) Disconnect wire connector from power vent
motor.
(4) Remove nut holding crank to vent glass.
(5) Remove bolts holding power vent motor to
D-pillar (Fig. 4).
(6) Remove power vent motor.
(7) Pull the crank system from the motor.
INSTALLATION
Before installing crank, cycle replacement motor to
the open position. Install crank hinge in extended
position to the motor and for installation, reverse the
above procedures.
POWER WINDOW SWITCH
To remove power window switches refer to Group
23, Body for proper procedures.
POWER WINDOW MOTOR
WARNING: DO NOT HAVE ANY HANDS OR FIN-
GERS IN SECTOR GEAR AREA WHERE THEY CAN
BE PINCHED BY SMALL MOVEMENTS OF REGULA-
TOR LINKAGE.
REMOVAL
(1) Tape the window in its existing position to
remove its weight from the regulator system.
(2) Cut and remove the tie wrap at the window
motor. Its no longer required.
(3) Disconnect window motor wire connector from
door harness.
(4) Remove screws and nuts holding window motor
to the inner panel.
(5) Remove the motor from the door inner panel,
let it hang from the cables.
(6) With the cables still attached to the failed
motor, Install the replacement motor to the door
inner panel. Tighten down the screws and nuts to 3.4
to 4.5 N´m ( 30 to 40 in. lbs.) of torque.
(7) Separate the failed motor from regulator by:
²Removing the drum cover plate.
²Lift the cable guide off the motor, the drum with
cables, will be lifted off simultaneously (Fig. 5).
CAUTION: Do not allow the drum to separate from
the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION
(1) Install the cable guide and drum into the
replacement motor.
Fig. 4 Vent Window Motor
NSPOWER WINDOWS 8S - 3
DIAGNOSIS AND TESTING (Continued)