engine CHRYSLER VOYAGER 2003 User Guide

ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformulat-
edº gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro-
vide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasoline free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may be
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle's catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
²The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)
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NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gel-
ling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and fol-
low the cold weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm up perfor-
mance.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.0 L (4.5 qts.)
Engine Oil* - 2.5 L
(Diesel)6.0 L (6.3 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with
Auxiliary Heater13.8 L (14.6 qts.)
Cooling System** -
3.3/3.8 L without Auxiliary
Heater12.6 L (13.4 qts.)
Cooling System** -
3.3/3.8 L with Auxiliary
Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-Speed)2.4-2.7 L (2.5-2.9 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.)
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
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FLUID TYPES (Continued)
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FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill point locations are located in
each applicable service manual section.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are located in each
applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
Maintenance Schedule Information not included in
this section, is located in the appropriate Owner's
Manual.
First is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É
F).L
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
²If equipped for and operating with E-85
(ethanol) fuel.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Second is ScheduleªAº. It is for vehicles that are
not operated under any of the conditions listed under
Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 minutes after a
fully warmed engine is shut off. Checking the oil level
while the vehicle is on level ground will improve the
accuracy of the oil level reading. Add oil only when the
level is at or below the ADD or MIN mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and add as needed.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Check the automatic transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Rotate the tires at each oil change interval
shown on Schedule ªAº 10 000 km (6,000 miles) or
every other interval shown on Schedule ªBº 10 000
km (6,000 miles).
SCHEDULE ªBº
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
Change the automatic transmission fluid and filter
every 77 000 km (48,000 miles) if the vehicle is usu-
ally operated under one or more of the conditions
marked with anL.
²
Day or night temperatures are below 0É C (32É F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C
(90É F).L
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
²If equipped for and operating with E-85
(ethanol) fuel.
RSLUBRICATION & MAINTENANCE0-7
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Miles 3, 000 6, 000 9, 000 12, 000 15, 000 18, 000
(Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) (29 000)
Change engine oil and engine
oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXXX X
Replace theengine air
cleaner filter.*X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.X
Inspect the generator belt on
2.4 liter engines, replace if
necessary.X
Change the All Wheel Drive
(AWD) power transfer unit
fluid. (See note at the end of
this chart)X
Replace the air conditioning
filter.X
Miles 21, 000 24, 000 27, 000 30, 000 33, 000 36, 000
(Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter,
replace if necessary. *XXX X X
Replace theengine air cleaner filter.X
Replace thespark plugs2.4 liter
engines.X
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering
pump belt tension on 2.4 liter engines.X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Inspect thePCV valveand replace as
necessary.*X
Change the All Wheel Drive (AWD) power
transfer unit fluid. (See note at the end of
this chart)X
Change the All Wheel Drive (AWD)
overrunning clutch and rear carrier fluid.
(See the note at the end of this chart)X
Replace the air conditioning filter. X X
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MAINTENANCE SCHEDULES (Continued)
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Miles 39, 000 42, 000 45, 000 48, 000 51, 000 54, 000
(Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *XX XX X
Replace theengine air cleaner filter.
*X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Change the automatic transaxle fluid and
filter.X
Change the All Wheel Drive power transfer
unit fluid. (See the note at the end of this
chart.)X
Change the All Wheel Drive (AWD)
overrunning clutch and rear carrier fluid.
(See note at the end of this chart)X
Replace the air conditioning filter. X
Miles 57, 000 60, 000 63, 000 66, 000 69, 000 72, 000
(Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter,
replace if necessary. *X XXX X
Replace theengine air cleaner filter.X
Replace thespark plugs
on 2.4 liter
engines.X
Replace theignition cables
on 2.4 liter
engines.X
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering
pump belt tension on 2.4 liter engines.X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Inspect thePCV valve
and replace if
necessary.*X
Inspect the serpentine drive belt on 3.3
liter and 3.8 liter engines, replace if
necessary.X
Change the All Wheel Drive (AWD)
power transfer unit fluid. (See note at the
end of this chart)XX
Change the All Wheel Drive (AWD)
overrunning clutch and rear carrier fluid.
(See note at the end of this chart)X
Replace the air conditioning filter. X X
RSLUBRICATION & MAINTENANCE0-9
MAINTENANCE SCHEDULES (Continued)
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Miles 75, 000 78, 000 81, 000 84, 000 87, 000 90, 000
(Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)
Change engine oil and engine
oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXXX
Replace theengine air
cleaner filterXX
Replace thespark plugson
3.3 liter and 3.8 liter
engines.X
Replace theignition cables
on 3.3 liter and 3.8 liter
engines.X
Replace thespark plugson
2.4 liter engines.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.XX
Inspect the generator belt on
2.4 liter engines, replace if
necessary.XX
Inspect the tie rod ends and
boot seals.X
Inspect engine accessory
drive belts on 3.3 liter and 3.8
liter engines, replace if
necessary. ³XX
Check thePCV valveand
replace if necessary. Not
required if previously
changed.*X
Change the All Wheel Drive
power transfer unit fluid. (See
the note at the end of this
chart.)XX
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See note at
the end of this chart)X
Replace theengine timing
belton 2.4 liter engines. *X
Replace the air conditioning
filter.X
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MAINTENANCE SCHEDULES (Continued)
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Miles 93, 000 96, 000 99, 000 100, 000 102, 000 105, 000
(Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)
Change engine oil and engine
oil filter.XXX X X
Inspect the brake linings. X
Inspect the engine air cleaner
filter, replace if necessary. *XXXXX
Replace theengine air
cleaner filter*X
Change the automatic
transmission fluid and filter.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.X
Inspect the generator belt on
2.4 liter engines, replace if
necessary.X
Inspect engine accessory
drive belts on 3.3 liter and 3.8
liter engines, replace if
necessary. ³X
Change the All Wheel Drive
(AWD) power transfer unit,
overrunning clutch and rear
carrier fluid. (See note at the
end of this chart)X
Flush and replace the engine
coolant at 60 months or
100,000 miles.X
Replace the air conditioning
filter.X
RSLUBRICATION & MAINTENANCE0-11
MAINTENANCE SCHEDULES (Continued)
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Miles 108, 000 111, 000 114, 000 117, 000 120, 000
(Kilometers) (173 000) (178 000) (182 000) (187 000) (192 000)
Change engine oil and engine oil filter.XXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 2.4 liter
engines.X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Inspect engine accessory drive belts on 3.3
liter and 3.8 liter engines, replace if
necessary. ³X
Inspect the tie rod ends and boot seals. X
Inspect thePCV valveand replace as
necessary.*X
Change the All Wheel Drive (AWD) power
transfer unit fluid. (See note at the end of
this chart)X
Replace the air conditioning filter. X X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.NOTE: The AWD power transfer unit fluid and the
AWD overrunning clutch/ rear carrier fluid must be
changed at the more frequent intervals shown in
schedule B if the vehicle is operated under any of
the conditions noted by a diamond at the beginning
of the schedule.
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MAINTENANCE SCHEDULES (Continued)
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SCHEDULE ªAº
Miles 6, 000 12, 000 18, 000 24, 000 30, 000 36, 000
(Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine
oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXXX X
Replace theengine air
cleaner filter.X
Replace thespark plugson
2.4 liter engines.X
Inspect the tie rod ends and
boot seals.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.X
Replace the air conditioning
filter.XX X
Miles 42, 000 48, 000 54, 000 60, 000 66, 000 72, 000
(Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *XXX X X
Replace theengine air cleaner filter.X
Replace thespark plugs
on 2.4 liter
engines.X
Replace theignition cables
2.4 liter
engines.X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.X
Inspect the tie rod ends and boot seals. X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check thePCV valve
and replace, if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
and 3.8 liter engines, replace if necessary. ³XX
Flush and replace the engine coolant at 60
months, regardless of mileage.X
Replace the air conditioning filter. X X X
RSLUBRICATION & MAINTENANCE0-13
MAINTENANCE SCHEDULES (Continued)
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Miles 78, 000 84, 000 90, 000 96, 000 100, 000
(Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter.XXXX
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *XX X X
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Check and replace thePCV valve,if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
and 3.8 liter engines, replace if necessary. ³X
Replace thespark plugs3.3 liter and 3.8
liter engines.X
Replace theignition cables3.3 liter and
3.8 liter engines.X
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.X
Replace the air conditioning filter. X X
Miles 102, 000 108, 000 114, 000 120, 000
(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Change engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace if necessary. * X X X
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter engines.X
Replace theignition cables2.4 liter engines.X
Inspect and adjust the power steering pump belt tension
on 2.4 liter engines.X
Inspect the tie rod ends and boot seals. X
Check thePCV valveand replace, if necessary.*X
Inspect the serpentine drive belt on 3.3 liter and 3.8 liter
engines, replace if necessary. ³X
Replace theengine timing belton 2.4 liter engines
only.X
Replace the air conditioning filter. X X
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MAINTENANCE SCHEDULES (Continued)
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