engine CHRYSLER VOYAGER 1996 Service Manual

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)

INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE...................... 1
E-MARK LABEL......................... 1MANUFACTURER PLATE.................. 3
VEHICLE IDENTIFICATION NUMBER......... 1
GENERAL INFORMATION
E-MARK LABEL
An E-mark Label (Fig. 1) 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
VEHICLE IDENTIFICATION NUMBER
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel next to the left A-pillar
(Fig. 2). The VIN consists of 17 characters in a com-
bination of letters and numbers that provide specific
information about the vehicle. Refer to the VIN
Decoding Information Table to interpret VIN code.
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 VIN. The check
digit is used by the manufacturer and government
agencies to verify the authenticity of the vehicle and
official documentation. The formula to use the check
digit is not released to the general public.
BODY CODE PLATE
LOCATION AND DECODING
The Body Code Plate is located (Fig. 3) 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.
BODY CODE PLATEÐLINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, 14, AND 15
Open Space
Fig. 1 E-Mark Label
Fig. 2 VIN PLATE LOCATION
NS/GSINTRODUCTION 1

DIGITS 16, 17, AND 18
Vehicle Shell Car Line
²GSYH = Voyager/Grand Voyager SE FWD
²GSYP = Voyager/Grand Voyager LE FWD
²GSYS = Voyager LX FWD
²GSCP = Voyager/Grand Voyager LE AWD
²GSCS = Voyager LX AWD
DIGIT 19
Price Class
²H = High Line
²P = Premium
²S = Special/SportDIGITS 20 AND 21
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATEÐLINE 2
DIGITS 1,2, AND 3
Paint Procedure
DIGIT 4
Open Space
VIN DECODING INFORMATION
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of origin 1 = United States or Austria
2 = Canada
2 Make C = Chrysler
D = Dodge
3 Vehicle Type 4 = Multipurpose Pass. Veh.
4 Gross Vehicle Weight Rating G = 2268-2721 kg (5001-6000 lbs)
5 Car Line C = Voyager/Grand Voyager AWD
Y = Voyager/Grand Voyager FWD
6 Series 4 = Voyager/Grand Voyager SE FWD
5 = Voyager/Grand Voyager LE FWD/AWD
6 = Voyager LX FWD/AWD
N = 5-Speed Manual Transmission
B = 4-Speed Automatic Transmission
7 Body Style 2 = Short Wheelbase 4-Door
3 = Short Wheelbase 3-Door
4 = Long Wheelbase Premium 4-Door
5 = Long Wheelbase Highline 4-door
7 = Short Wheelbase Commercial Van
8 Engine B = 2.4 L 4cyl. MPI 16-Valve DOHC
C = 2.0L 4cyl. MPI 16-Valve SOHC
M = 2.5L 4cyl Turbo Diesel (Intercooler)
R = 3.3 L 6 cyl. gas MPI
L = 3.8 L 6 cyl. gas MPI
9 Check Digit See explanation in this section.
10 Model Year W = 1998
11 Assembly Plant B = St. Louis South, U.S.A.
R = Windsor, Canada
U = Graz, Austria
12 Build Sequence 6 Digit number assigned by assembly plant
2 INTRODUCTIONNS/GS
GENERAL INFORMATION (Continued)

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 Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²ECB = 2.0L 4cyl 16 valve SOHC gasoline
²EDZ = 2.4 L 4 cyl. 16 valve DOHC gasoline
²ENC = 2.5 L 4 cyl. Turbo Diesel (Intercooler)
²EGA = 3.3 L 6 cyl. gasoline
²EGH = 3.8 L 6 cyl. gasoline
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGL = 41TE 4-speed Electronic Automatic Tran-
saxle
²DD3 = A-598 5±speed Manual TransaxleDIGIT 4
Open Space
DIGIT 5
Market Code
²B = International
²M = Mexico
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number (VIN)
Refer to Vehicle Identification Number (VIN) para-
graph 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 contin-
ued (CTD).
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
MANUFACTURER PLATE
The Manufacturer Plate (Fig. 4) is located in the
engine compartment on the radiator closure panel
crossmember adjacent to the Body Code Plate. The
plate contains five lines of information:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
Fig. 3 Body Code Plate
Fig. 4 Manufacturer Plate
NS/GSINTRODUCTION 3
GENERAL INFORMATION (Continued)

LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION................... 1
JUMP STARTING, HOISTING AND TOWING.... 7MAINTENANCE SCHEDULES................ 3
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS........... 1
FLUID CAPACITIES....................... 2
INTERNATIONAL SYMBOLS................ 1INTRODUCTION......................... 1
PARTS AND LUBRICANT
RECOMMENDATIONS.................... 1
GENERAL INFORMATION
INTRODUCTION
Service and maintenance procedures for compo-
nents and systems listed in Schedule ± A or B can be
found by using the Group Tab Locator index at the
front of this manual. If it is not clear which group
contains the information needed, refer to the index at
the back of this manual.
There are two maintenance schedules that show
proper service based on the conditions that the vehi-
cle is subjected to.
Schedule ±A, lists scheduled maintenance to be
performed when the vehicle is used for general trans-
portation.
Schedule ±B, lists maintenance intervals for vehi-
cles that are operated under the conditions listed at
the beginning of the Maintenance Schedule section.
Use the schedule that best describes your driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
PARTS AND LUBRICANT RECOMMENDATIONS
When service is required, Chrysler Corporation
recommends that only Mopartbrand parts, lubri-
cants and chemicals be used. Mopar provides the
best engineered products for servicing Chrysler Cor-
poration vehicles.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to
identify engine compartment lubricant and fluid
inspection and fill locations (Fig. 1).
CLASSIFICATION OF LUBRICANTS
Only lubricants that are endorsed by the following
organization should be used to service a Chrysler
Corporation vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 2)
²National Lubricating Grease Institute (NLGI)
(Fig. 3)
Fig. 1 International Symbols
NSLUBRICATION AND MAINTENANCE 0 - 1

ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity 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.
API QUALITY CLASSIFICATION
The API Service Grade specifies the type of perfor-
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils.
Use engine oils that are API Service Certified.
5W-30 and 10W-30 MOPAR engine oils conform to
specifications.
Refer to Group 9, Engine for engine oil specifica-
tion.
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
symbol 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.
FLUID CAPACITIES
Fuel Tank.......................76L(20gal.)
Engine Oil, With Filter............4.3 L (4.5 qts.)
Engine Oil, W/O Filter.............3.8 L (4.0 qts.)
Cooling System 2.4L Engine........9.0 L (9.5 qts.)
Cooling System 3.OL Engine.......9.5 L (10.5 qts.)
Cooling System 3.3 or 3.8L Engine . .9.5 L (10.5 qts.)
Automatic Transaxle Service Fill.....3.8 L (4.0 qts.)
Automatic Transaxle
31TH/O-haul Fill...............8.0 L (8.5 qts.)
Automatic Transaxle
41TE/O-haul Fill...............8.6 L (9.1 qts.)
Power Steering.................0.81 L (1.7 pts.)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
0 - 2 LUBRICATION AND MAINTENANCENS
GENERAL INFORMATION (Continued)