change time CHRYSLER VOYAGER 2004 Service Manual

FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
For best results, a refueling pattern that alternates
between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recom-
mended that
²you do not switch when the fuel gauge indicates
less than 1/4 full
²you do not add less than 5 gallons when refuel-
ing
²you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in
driveability during warm up.
FFV STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0ÉF. In
the range of 0ÉF to 32ÉF, you may experience an
increase in the time it takes for your engine to start,
and a deterioration in driveability (sags and/or hesi-
tations) until the engine is fully warmed up.
Engine Operating on E-85 Fuel
If vehicle operates on E-85 fuel either full or part-
time, use only MopartFlexible Fuel 5W-30 engine oil
or an equivalent that meets DaimlerChrysler Stan-
dard MS-9214. Equivalent commercial Flexible Fuel
engine oils may be labeled as Multi-Fuel, Variable
Fuel, Flexible Fuel, etc. These engine oils may be
satisfactory if they meet the DaimlerChrysler Stan-
dard.
SAE 5W-30 engine oil is preferred for use in Flex-
ible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
CRUISING RANGE
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for these transaxles.NOTE: All transaxles have a common transmission
and differential sump. Filling the transaxle accom-
modates the differential as well.
TRANSMISSION FLUID
MopartATF+4 (Automatic Transmission Fluid) is
required in the 41TE automatic and T850 manual
transaxles. Substitute fluids can induce transmission
problems and/or failure.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
0 - 4 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

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
DESCRIPTION
There are two maintenance schedules that show
therequiredservice for your vehicle.
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 32É F (0É
C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90É F (32É C).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
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 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 automatic transmission fluid level.
²Check the coolant level, hoses, and clamps.
Tire Rotation
²Rotate the tires at 6,000 miles (10 000 km).
SCHEDULE B
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 60,000 miles (96 000 km) if the vehicle is usu-
ally operated under one or more of the conditions
marked with anL.
²Day or night temperatures are below 32É F (0É
C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90É F (32É C).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
RSLUBRICATION & MAINTENANCE0-7

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 automatic transaxle 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 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 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.
0 - 12 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

* 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.
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.
DESCRIPTION - 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.
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).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
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 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 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 automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Rotate the tires at each oil change interval
shown on Schedule ªAº 12 000 km (7,500 miles) or
every other interval shown on Schedule ªBº 10 000
km (6,000 miles).
RSLUBRICATION & MAINTENANCE0-15
MAINTENANCE SCHEDULES (Continued)

Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
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. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 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.XX
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check and replace thePCV valve,if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
engines, replace if necessary. ³XX
Replace thespark plugs3.3 liter engines. X
Replace theignition cables3.3 liter
engines.X
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.X
Replace theengine timing belton 2.4 liter
engines only.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.
RSLUBRICATION & MAINTENANCE0-17
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)

DIAGNOSIS AND TESTING - HUB AND
BEARING
The condition of the front hub and bearing assem-
bly is diagnosed using the inspection and testing pro-
cedure detailed below.
The bearing contained in the Unit III front hub/
bearing assembly will produce noise and vibration
when worn or damaged. The noise will generally
change when the bearings are loaded. A road test of
the vehicle is normally required to determine the
location of a worn or damaged bearing.
Find a smooth level road surface and bring the
vehicle up to a constant speed. When vehicle is at a
constant speed, swerve the vehicle back and forth
from the left and to the right. This will load and
unload the bearings and change the noise level.
When bearing damage is slight, the noise is some-
times noticeable at lower speeds and at other times
is more noticeable at speeds above 105 km/h (65
mph).
REMOVAL
NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to
remove the steering knuckle from the vehicle. In the
event that the hub/bearing is frozen in the steering
knuckle and cannot be removed by hand, it will
have to be pressed out of the steering knuckle. The
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
pressed out of the steering knuckle. (Refer to 2 -
SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove wheel lug nuts, and front tire and
wheel assembly.
(3) Remove the cotter pin, nut lock and spring
washer from the stub axle (Fig. 4).
(4) With aid of a helper applying the brakes to
keep the front hub from turning, remove the hub nut
(Fig. 4).
(5) Remove disc brake caliper and adapter as an
assembly from knuckle as shown (Fig. 5). Hang
assembly out of the way using a bungee cord or wire.
Do not allow caliper hang by brake hose.
(6) Remove brake rotor from hub and bearing (Fig.
5).
(7) Push in on end of driveshaft stub shaft, push-
ing its splines out of the hub splines.
Fig. 4 Hub Nut
1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
Fig. 5 Front Brake Mounting
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
RSFRONT SUSPENSION2-5
HUB / BEARING (Continued)