wheel CHRYSLER VOYAGER 2004 Service Manual

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
5sBrakes
6Clutch
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8EsElectronic Control Modules
8FEngine Systems
8FsEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8NsPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
9sEngine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission/Transaxle
21sTransmission/Transaxle
22Tires/Wheels
22sTires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

DIGIT 21
Price Class
²H = Highline
²L = Lowline
²P = Premium
²S = Luxury
²X = Premium
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 7
Primary Paint (Refer to 23 - BODY/PAINT - SPEC-
IFICATIONS).
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline
(MPI)
²EGA = 3.3L 6 cyl. Gasoline (SMPI)
²EGH = 3.8L 6 cyl. Gasoline (SMPI)
²EGM = 3.3L 6 cyl. Ethanol Flexible Fuel
²ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGC = 31TH 3-Speed Automatic Transaxle
²DGL = 41AE/TE 4-Speed Electronic Automatic
²DDR = T850 5-Speed Manual 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.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
2 INTRODUCTIONRS
BODY CODE PLATE (Continued)

POSITION INTERPRETATION CODE = DESCRIPTION
6 Series 2 = Low Line
3 = Medium
4 = High Line
5 = Premium
6 = Sport
7 = Special
6 - Export Series B = 4-Speed Automatic Transaxle
N = 5-Speed Manual Transaxle
7 Body Style 1 = Caravan Commercial Van Short Wheelbase
4 = Grand Caravan Commercial Van Long Wheelbase
4 = Grand Caravan/Town & Country Long Wheelbase
5 = Caravan/Voyager Wagon Short Wheelbase
7 - Export Body Style 1 = EURO Wagon-Long Wheelbase RG-53-S Series
2 = EURO Wagon-Short Wheelbase RG-52-H Series
3 = EURO Wagon-Short Wheelbase RG-52-P Series
4 = EURO Wagon-Long Wheelbase RG-53-P Series
5 = EURO Wagon-Long Wheelbase RG-53-H Series
6 = Commercial Van-Short Wheelbase with-CYX Less
AS8
7 = Commercial Van-Short Wheelbase with AS8
8 = Commercial Van-Long Wheelbase Highline with-CYX
9 = Commercial Van-Long Wheelbase Premium Line
with-CYX
CYX = No Rear Seat Package
AS8 = Interior Delete Group
8 Engine B = 2.4L 4 Cyl. 16-Valve Gasoline DOHC (MPI)
L = 3.8L 6 Cyl. Gasoline (SMPI)
R = 3.3L 6 Cyl. Gasoline (SMPI)
7 = 2.5L 4 Cyl. 16 Valve Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 4 = 2004
11 Assembly Plant B = St. Louis Assembly South
R = Windsor Assembly
U = Eurostar Gesellschaftz Assembly
12 through 17 Sequence Number A six digit number assigned by assembly plant.
10 INTRODUCTIONRS
VEHICLE IDENTIFICATION NUMBER (Continued)

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
letter ªGº. Chassis lubricant is identified by the letter
ªLº. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
The information in this section is for Flexible Fuel
Vehicles (FFV) only. These vehicles can be identified
by the unique Fuel Filler Door Label that states
Ethanol (E-85) or Unleaded Gasoline Only. This sec-
tion only covers those subjects that are unique to
these vehicles. Please refer to the other sections of
this manual for information on features that are
common between Flexible Fuel and gasoline only
powered vehicles.
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel etha-
nol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
cle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-3
FLUID TYPES (Continued)

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
0 - 8 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

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 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. X X X X X 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 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
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)

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
0 - 10 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

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
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)

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)

SCHEDULE B - EXPORT ONLY
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 96 000 km (60,000 miles) if the vehicle is usu-
ally operated under one or more of the conditions
marked with anL.
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.
Kilometers 5 000 10 000 14 000 19 000 24 000 29 000
(Miles) (3,000 ) (6,000 ) (9,000) (12,000) (15,000) (18,000)
Change engine oil and engine
oil filter.XX XXX 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 All Wheel Drive
(AWD) power transfer unit
fluid. (See note at the end of
this chart)X
Replace the air conditioning
filter.X
Kilometers 34 000 38 000 43 000 48 000 53 000 58 000
(Miles) (21,000) (24,000) (27,000) (30,000) (33,000) (36,000)
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
0 - 18 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)