oil CHRYSLER VOYAGER 2004 Owner's Manual

Kilometers 120 000 125 000 130 000 134 000 139 000 144 000
(Miles) (75,000) (78,000) (81,000) (84,000) (87,000) (90,000)
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 engines.X
Replace theignition cables
on 3.3 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
engines, replace if necessary.
³XX
Change the manual
transmission fluid.X
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.XX
RSLUBRICATION & MAINTENANCE0-21
MAINTENANCE SCHEDULES (Continued)

Kilometers 149 000 154 000 158 000 160 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000)
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
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
engines, replace if necessary.
³X
Change the manual
transmission fluid.X
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
0 - 22 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change engine oil and engine oil filter. X X X X 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 engines, replace if necessary. ³X
Inspect the tie rod ends and boot seals. X
Inspect thePCV valveand replace as
necessary.*X
Change the automatic transmission fluid
and filter.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
* 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 bechanged at the intervals shown in schedule B if the
vehicle is operated under any of the conditions
noted by a diamond at the beginning of the sched-
ule.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
RSLUBRICATION & MAINTENANCE0-23
MAINTENANCE SCHEDULES (Continued)

DESCRIPTION ± DIESEL ENGINES ± EXPORT
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under
Schedule9B9.
Second is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Extensive engine idling.
²Driving in dusty conditions.
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
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 willimprove 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 the 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 deaeration bot-
tle, brake master cylinder and transmission, 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 manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Inspect engine accessory drive belts. Replace as
necessary.
²Inspect for the presence of water in the fuel fil-
ter/water separator unit.
²Rotate the tires at each oil change interval (20
000 km).
SCHEDULE A - DIESEL ENGINES
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000
km
Change engine oil and engine oil filter.XXXX X
Inspect engine air filter element. Replace as
necessary.XX X
Replace engine air filter element X X
Replace fuel filter/water separator unit.XXXX X
Inspect timing belt tensioner and replace if
necessary. ³X
Replace engine timing belt and idler
pulleys.X
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings.XXXX X
0 - 24 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 120 000
km140 000
km160 000
km180 000
km
Change engine oil and engine oil filter. X X X X
Inspect engine air filter element. Replace as necessary. X X
Inspect accessory drive belts and replace if necessary. X
Replace engine air filter element X X
Replace fuel filter/water separator unit. X X X X
Flush and replace engine coolant. X
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings. X X X X
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.³ Replace if there is superficial wear, bearing clear-
ance, or evident grease leakage.
SCHEDULE B - DIESEL ENGINES
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
²Extensive engine idling.
²Driving in dusty conditions.²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km
Change engine oil and engine oil filter.XXXX X
Inspect engine air filter element. Replace as
necessary.XX X
Replace engine air filter element X X
Replace fuel filter/water separator unit. X X
Check front end alignment. X X
Change the manual transaxle fluid. X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings.XXXX X
RSLUBRICATION & MAINTENANCE0-25
MAINTENANCE SCHEDULES (Continued)

Kilometers 60 000
km70 000 km 80 000 km 90 000 km 100 000
km
Change engine oil and engine oil filter. X X X X X
Inspect engine air filter element. Replace as
necessary.XX
Replace engine air filter element X X X
Replace fuel filter/water separator unit. X X X
Inspect timing belt tensioner and replace if
necessary. ³X
Replace engine timing belt and idler pulleys. X
Check front end alignment. X X
Change the manual transaxle fluid. X X
Inspect the tie rod ends and boot seals. X
Inspect the brake linings. X X X X X
Kilometers 110 000
km120 000
km130 000
km140 000
km150 000
km160 000
km
Change engine oil and engine
oil filter.XXXXX X
Inspect engine air filter
element. Replace as
necessary.XXX
Inspect accessory drive belts
and replace if necessary.X
Replace engine air filter
elementXX X
Replace fuel filter/water
separator unit.XX X
Flush and replace engine
coolant.X
Check front end alignment. X X X
Inspect the tie rod ends and
boot seals.XX
Inspect the brake linings. XXXXX X
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
³ Replace if there is superficial wear, bearing clear-
ance, or evident grease leakage.WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
0 - 26 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

TOWING
STANDARD PROCEDURE - TOWING
WARNINGS AND CAUTIONS
WARNING: DO NOT ALLOW TOWING ATTACHMENT
DEVICES TO CONTACT THE FUEL TANK OR LINES,
FUEL LEAK CAN RESULT.
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
REAR BUMPER.
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-
tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams
use:
²FWD vehicles, use of a flat bed towing device or
a wheel lift is recommended (Fig. 7).
²AWD vehicles, a flat bed towing device or a
wheel lift and towing dolly is recommended (Fig. 7).
When using a wheel lift towing device, be sure the
disabled vehicle has at least 100 mm (4 in.) ground
clearance. If minimum ground clearance cannot be
reached, use a towing dolly. If a flat bed device is
used, the approach angle should not exceed 15
degrees.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehicle should be raised until the lifted
wheels are a minimum 100 mm (4 in.) from the
ground. Be sure there is at least 100 mm (4 in.)
clearance between the tail pipe and the ground. If
necessary, remove the wheels from the front end ofthe vehicle and lower the front end closer to the
ground, to increase the ground clearance at the rear
of the vehicle. Install lug nuts on wheel attaching
studs to retain brake drums or rotors.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed with the
front wheels on the ground, use a towing dolly or flat
bed hauler.
FLAT TOWING WITH TOW BAR
²Three speed automatic transaxle vehicles can be
flat towed at speeds not to exceed 40 km/h (25 mph)
for not more than 25 km (15 miles). The steering col-
umn must be unlocked and gear selector in neutral.
²Four speed electronic automatic transaxle vehi-
cles can be flat towed at speeds not to exceed 72
km/h (44 mph) for not more than 160 km (100 miles).
The steering column must be unlocked and gear
selector in neutral.
²AWD models should not be flat towed. For addi-
tional information, refer toRECOMMENDED TOW-
ING EQUIPMENTin this section.
FLAT BED TOWING TIE DOWNS
CAUTION: Do not tie vehicle down by attaching
chains or cables to suspension components or
engine mounts, damage to vehicle can result.
The vehicle can be tied to a flat bed device using
the two pair of front slots on the bottom surface of
the rails, behind the front wheels. The two pair of
rear slots on the bottom of the rail between the
bumper extension bolts and on the bottom of the rail
just rearward of the jounce bumper. Vehicles
equipped with a rear sway bar have brackets at this
location.
Fig. 7 RECOMMENDED TOWING
1 - WHEEL LIFT
2 - FLAT BED
RSLUBRICATION & MAINTENANCE0-29

(2) Position stabilizer bar into front suspension
cradle so stabilizer bar bushings are aligned with
depressions in cradle. Install stabilizer bar bushing
retainers onto crossmember aligning raised bead on
retainer with cutouts in bushings (Fig. 36).Do not
tighten Stabilizer bar bushing retainers bolts at
this time.
(3) Check position of the stabilizer bar in the front
suspension cradle. The center of the curved section of
the stabilizer bar must be aligned with the raised
line in the center of the front suspension cradle (Fig.
37).
(4) Install the stabilizer bar link mounting stud
through the hole in each end of the stabilizer bar
(Fig. 33).
CAUTION: When installing the nut on the mounting
stud of the stabilizer bar link, do not allow the stud
to rotate in it's socket. Hold the stud from rotating
by placing an open-end wrench on the flat
machined into the stud (Fig. 33).
(5) Hand-thread the nut on the end of each stabi-
lizer bar link stud. Hold the studs from turning by
placing an open-end wrench on the flat machined
into the link's mounting stud, then tighten each nut
while holding the wrench in place (Fig. 33). Tighten
each nut to a torque of 88 N´m (65 ft. lbs.).
(6) Tighten the stabilizer bar bushing retainer to
cradle attaching bolts (Fig. 34) to 68 N´m (50 ft. lbs.)
torque.
(7) Install the reinforcement on the front suspen-
sion cradle crossmember and install the bolts attach-ing the reinforcement to the cradle crossmember
(Fig. 32). Tighten the M-14 size bolts to a torque of
153 N´m (113 ft. lbs.). Tighten the M-12 size bolts to
a torque of 106 N´m (78 ft. lbs.).
(8) Install the lower control arm rear bushing
retainer bolts through reinforcement on each side of
each lower control arm rear bushing. Tighten these
M-10 size bolts to a torque of 61 N´m (45 ft. lbs.).
(9) Install the two bolts and bushings attaching
the reinforcement and rear of cradle crossmember to
body of vehicle (Fig. 32). Tighten bolts to a torque of
163 N´m (120 ft. lbs.).
(10) Install the power steering cooler (Fig. 31).
Tighten bolts to a torque of 11 N´m (100 in. lbs.).
(11) Lower the vehicle.
STRUT
DESCRIPTION - STRUT ASSEMBLY
A Macpherson type strut assembly is used in place
of a conventional front suspension's upper control
arm and upper ball joint. The bottom of the strut
mounts directly to the steering knuckle using two
bolts and nuts going through the strut clevis bracket
and steering knuckle. The top of the strut mounts
directly to the strut tower of the vehicle using the
threaded studs on the strut assemblies upper mount.
The strut assembly includes the components listed
in the figure (Fig. 38).
Each component is serviced by removing the strut
assembly from the vehicle and disassembling it.
The coil springs are side-oriented. Springs on the
left side of the vehicle have a left-hand wind top-to-
Fig. 36 Stabilizer Bar Bushing Retainer Installation
1-SWAYBAR
2 - SWAY BAR BUSHING
3 - BUSHING SPLIT
4 - FRONT SUSPENSION CRADLE
5 - BUSHING CUT-OUT
6 - BUSHING RETAINER
7 - RAISED BEAD
Fig. 37 Stabilizer Bar Correctly Positioned In Cradle
1 - RAISED BEAD
2-SWAYBAR
3 - WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE
SUSPENSION CRADLE MUST BE IN THE CENTER OF RADIUS
IN SWAY BAR
4 - FRONT SUSPENSION CRADLE
RSFRONT SUSPENSION2-19
STABILIZER BAR (Continued)

bottom while springs on the right side have a right-
hand wind top-to-bottom. This helps provide better
vehicle stability during jounce and rebound maneu-
vers of the front suspension. Left and right springs
must not be interchanged. Coil springs are rated sep-
arately for each corner or side of the vehicle depend-
ing on optional equipment and type of vehicle
service. If the coil springs require replacement, be
sure that the springs are replaced with springs meet-
ing the correct load rating and spring rate for the
vehicle and its specific options.
OPERATION - STRUT ASSEMBLY
The strut assembly cushions the ride of the vehicle,
controlling vibration, along with jounce and rebound
of the suspension.
The coil spring controls ride quality and maintains
proper ride height.
The spring isolators isolate the coil spring at the
top and bottom from coming into metal-to-metal con-
tact with the upper seat and strut.
The jounce bumper limits suspension travel and
metal-to-metal contact under full jounce condition.The strut dampens jounce and rebound motions of
the coil spring and suspension.
During steering maneuvers, the strut assembly
(through a pivot bearing in the upper strut mount)
and steering knuckle (through the lower ball joint)
turn as an assembly.
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
(1) Inspect for damaged or broken coil springs
(Fig. 38).
(2) Inspect for torn or damaged strut assembly
dust boots (Fig. 38).
(3) Inspect the coil spring isolator on the lower
spring seat for any signs of damage or deterioration.
(4) Lift dust boot (Fig. 39) and inspect strut
assembly for evidence of fluid running from the
upper end of fluid reservoir. (Actual leakage will be a
stream of fluid running down the side and dripping
off lower end of unit). A slight amount of seepage
between the strut rod and strut shaft seal is not
unusual and does not affect performance of the strut
assembly (Fig. 39). Also inspect jounce bumpers for
signs of damage or deterioration.
Fig. 38 STRUT ASSEMBLY
1 - NUT 6 - COIL SPRING
2 - UPPER MOUNT 7 - DUST SHIELD
3 - PIVOT BEARING 8 - JOUNCE BUMPER
4 - UPPER SPRING SEAT 9 - LOWER SPRING ISOLATOR
5 - UPPER SPRING ISOLATOR 10 - STRUT (DAMPER)
2 - 20 FRONT SUSPENSIONRS
STRUT (Continued)

For the disassembly and assembly of the strut
assembly, use of Strut Spring Compressor, Pentastar
Service Equipment (PSE) tool W-7200, or the equiva-
lent, is recommended to compress the coil spring.
Follow the manufacturer's instructions closely.
WARNING: DO NOT REMOVE THE STRUT SHAFT
NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE
AND MUST BE COMPRESSED, REMOVING SPRING
TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.(1) Position the strut assembly in the strut coil
spring compressor following the manufacturers
instructions. Position the lower hooks on the coil
spring first. The strut clevis bracket should be posi-
tioned straight outward from the compressor.
(2) Turn the upper mount of the strut assembly
toward the inside of the compressor as shown to
allow positioning of the compressor upper hooks (Fig.
44). Position the upper hooks on top of the coil spring
upper seat approximately 1 inch from outside diame-
ter of seat (Fig. 47).Do not allow hooks to be
placed closer to edge.Place a clamp on the lower
end of the coil spring, so the strut is held in place
once the strut shaft nut is removed.
(3) Compress the coil spring until all coil spring
tension is removed from the upper mount.
(4) Install Strut Nut Socket, Special Tool 6864, on
the strut shaft retaining nut (Fig. 45). Next, install a
10 mm socket on the hex on the end of the strut
shaft. While holding the strut shaft from turning,
remove the nut from the strut shaft.
(5) Remove the upper mount from the strut shaft.
(6) If the pivot bearing needs to be serviced,
remove it from the top of the coil spring upper seat
by pulling it straight up.
(7) Remove the clamp from the bottom of the coil
spring and remove the strut out through the bottom
of the coil spring.
NOTE: If the coil spring or upper spring seat needs
to be serviced, proceed with the next step, other-
wise, proceed with step 10.
Fig. 42 Strut Damper Attachment To Steering
Knuckle
1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
3 - TIE ROD END
4 - ROTOR
5 - STEERING KNUCKLE
Fig. 43 Strut Assembly To Strut Tower Attaching
Nuts (Typical)
1 - WINDSHIELD WIPER MODULE
2 - STRUT TOWER
3 - STRUT MOUNT ATTACHING BOLTS
4 - UPPER STRUT MOUNT
Fig. 44 Mount Rotated And Hooks Positioned
1 - UPPER MOUNT TURNED TOWARD COMPRESSOR
2 - COMPRESSOR UPPER HOOKS
3 - UPPER SPRING SEAT
2 - 22 FRONT SUSPENSIONRS
STRUT (Continued)