oil change CHRYSLER VOYAGER 2005 User Guide

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.
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).
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.XXXXX X
Rotate Tires X X 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
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
Rotate Tires X X 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 - 16 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

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)
Inspect the generator belt on
2.4 liter engines, replace if
necessary.X
Inspect thePCV valveand
replace as necessary.*X
Change the manual
transmission fluid.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
Kilometers 62 000 67 000 72 000 77 000 82 000 86 000
(Miles) (39,000) (42,000) (45,000) (48,000) (51,000) (54,000)
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires X X 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 manual
transmission fluid.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
RSLUBRICATION & MAINTENANCE0-17
MAINTENANCE SCHEDULES (Continued)

Kilometers 91 000 96 000 101 000 106 000 110 000 115 000
(Miles) (57,000) (60,000) (63,000) (66,000) (69,000) (72,000)
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires 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 plugson
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 valveand
replace if necessary.*X
Inspect the serpentine drive
belt on 3.3 liter engines,
replace if necessary.X
Change the automatic
transmission fluid and filter.LX
Change the manual
transmission fluid.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
0 - 18 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

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
Rotate Tires X X 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 & MAINTENANCE0-19
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
Rotate Tires 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
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.XXXX X
Rotate Tires 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
0 - 20 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)
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.LX
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.
LThis maintenance is required only for police,
taxi, limousine type operation, or trailer towing.
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.
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 - 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).
Most vehicles are operated under the conditions
listed for Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
Failure to perform the required maintenance 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 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.
RSLUBRICATION & MAINTENANCE0-21
MAINTENANCE SCHEDULES (Continued)

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.
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
Rotate TiresXXXX X
Replace engine air filter elementXXXX X
Replace fuel filter/water separator unit.XXXX X
Inspect timing belt tensioner. ³X
Replace the 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
Kilometers 120 000
km140 000
km160 000
km180 000
km200 000
km
Change engine oil and engine oil filter.XXXXX
Rotate TiresXXXX X
Inspect accessory drive belts and replace if
necessary.X
Replace engine air filter elementXXXX X
Replace fuel filter/water separator unit.XXXXX
Replace the timing belt, idler pulleys and
timing belt tensioner.X
Flush and replace engine coolant. X
Check front end alignment. X X X
Inspect the tie rod ends and boot seals. X X X
Inspect the brake linings.XXXXX
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.
0 - 22 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

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
Rotate Tires X X
Replace engine air filter elementXXXX X
Replace engine accessory drive belt. X
Replace the engine timing belt and idler
pulleys.X
Inspect timing belt tensioner. ³X
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
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000
km
Change engine oil and engine oil filter.XXXX X
Rotate Tires X X X
Replace engine air filter elementXXXX X
Replace fuel filter/water separator unit. X X X
Replace engine accessory drive belt. X
Replace engine timing belt, idler pulleys
and timing belt tensioner.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.XXXX X
Kilometers 110 000
km120 000
km130 000
km140 000
km150 000
km160 000
km
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires X X X
Replace engine air filter
elementXXXXX X
Replace engine accessory
drive belt.X
Replace the engine timing
belt and idler pulleys.X
Inspect timing belt tensioner.
³X
RSLUBRICATION & MAINTENANCE0-23
MAINTENANCE SCHEDULES (Continued)

(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-
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.
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)

(10) Remove the dust shield and jounce bumper as
an assembly from the strut shaft by pulling both
straight up and off the strut shaft. The dust shield
cannot be separated from the jounce bumper until
after it is removed from strut shaft.
(11) Remove the jounce bumper from the dust
shield. The jounce bumper is removed from the dust
shield by collapsing the dust shield until the jounce
bumper can be pulled free from the dust boot.
(12) Remove the spring isolator from the lower
spring seat on the strut (Fig. 38).
(13) Inspect the strut assembly components (Fig.
38) for the following and replace as necessary:
²Inspect the strut for any condition of shaft bind-
ing over the full stroke of the shaft.
²Check the upper mount for cracks and distortion
and its retaining studs for any sign of damage.
²Check the upper seat for stress cracks and wear.
²Check the upper spring isolator for severe dete-
rioration.
²Check for binding of the strut assembly pivot
bearing.
²Inspect the dust shield for rips and deteriora-
tion.
²Inspect the jounce bumper for cracks and signs
of deterioration.
ASSEMBLY - STRUT ASSEMBLY
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.
NOTE: Coil Springs on this vehicle are side-ori-
ented. Springs on the left side of the vehicle have a
left-hand wind top-to-bottom while springs on the
right side have a right-hand wind top-to-bottom.
Left and right springs must not be interchanged.
NOTE: If the coil spring has been removed from the
spring compressor, proceed with the next step, oth-
erwise, proceed with step 5.
(1) Place the coil spring in the compressor lower
hooks following the manufacturers instructions.
Proper orientation of the spring to the strut (once
installed) is necessary. Consider the following when
placing the coil spring in the compressor: From
above, the compressor back is at the 12 o'clock posi-
tion, and you, standing in the front of the compres-
sor, are at the 6 o'clock position. Place the lower coil
spring end at the 12 o'clock position for left springs
and at the 6 o'clock position for right springs. (Fig.
46).(2) Install the upper seat and upper isolator on top
of the coil spring. Position the notch in the perimeter
of the upper seat toward the front of the compressor
(same 6 o'clock position as in step 1).
(3) Position the upper hooks on top of the coil
spring upper seat so the upper hooks span approxi-
mately 1 inch past outside diameter of upper seat
(Fig. 47). This will allow proper clearance for upper
mount installation without pinching the hooks in-be-
tween the two pieces.Do not allow hooks to be
placed closer to edge.
(4) Compress the coil spring far enough to allow
strut installation.
(5) If the pivot bearing has been removed from the
upper seat, install the pivot bearing on the top of the
Fig. 46 Spring Positioned In Compressor (Right
Spring Shown)
1 - COMPRESSOR LOWER HOOKS
2 - COIL SPRING END
Fig. 47 Hook Placement On Upper Seat
1 - HOOKS POSITIONED 1 INCH FROM EDGE
2 - PIVOT BEARING AND UPPER SEAT
RSFRONT SUSPENSION2-23
STRUT (Continued)