ignition CHRYSLER VOYAGER 2005 Service Manual

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

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 ªreformu-
latedº gasoline. Reformulated gasoline contain oxy-
genates, 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 beadversely 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.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)

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
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
Inspect the tie rod ends and
boot seals.X
Inspect thePCV valveand
replace if necessary.*X
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
³X
Change the automatic
transmission fluid and filter.LX
Replace the air conditioning
filter.XX
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
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 and 3.8 liter engines.X
Replace theignition cables
3.3 liter and 3.8 liter engines.X
Inspect the tie rod ends and
boot seals.X
Check thePCV valveand
replace if necessary. Not
required if previously
changed.*X
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary. ³XX
Replace the air conditioning
filter.X
RSLUBRICATION & MAINTENANCE0-9
MAINTENANCE SCHEDULES (Continued)

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
Rotate TiresXXXX
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *XX X X
Replace theengine air cleaner filter.X
Inspect the tie rod ends and boot seals. 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
Rotate Tires 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
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. ³XX
Flush and replace the engine coolant at 120 months, if
not done at 100,000 miles (160 000 km).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.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 - 12 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 84 000 96 000 108 000 120 000 132 000 144 000
(Miles) (52,500) (60,000) (67,500) (75,000) (82,500) (90,000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *X XXX
Replace theengine air
cleaner filter.XX
Replace thespark plugson
2.4 liter engines.XX
Replace theignition cables
on 2.4 liter engines.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.XX
Inspect the tie rod ends and
boot seals.XX
Inspect the generator belt on
2.4 liter engines, replace if
necessary.XX
Check thePCV valveand
replace, if necessary.*XX
Inspect the serpentine drive
belt on 3.3 liter engines,
replace if necessary. ³XX X
Flush and replace the engine
coolant at 60 months,
regardless of mileage.X
Replace the air conditioning
filter.XX X
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
Rotate Tires 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
0 - 14 LUBRICATION & MAINTENANCERS
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]
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 & MAINTENANCE0-15
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)

JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS. (Refer to 8 - ELECTRICAL/BAT-
TERY SYSTEM/BATTERY - STANDARD PROCE-
DURE).
WARNING: DO NOT JUMP START A FROZEN BAT-
TERY, PERSONAL INJURY CAN RESULT.
WARNING: DO NOT JUMP START WHEN MAINTE-
NANCE FREE BATTERY INDICATOR DOT IS BRIGHT
COLOR.
WARNING: DO NOT ALLOW JUMPER CABLE
CLAMPS TO TOUCH EACH OTHER WHEN CON-
NECTED TO A BOOSTER SOURCE.
WARNING: DO NOT USE OPEN FLAME NEAR BAT-
TERYWARNING: REMOVE METALLIC JEWELRY WORN
ON HANDS OR WRISTS TO AVOID INJURY BY
ACCIDENTAL ARCING OF BATTERY CURRENT.
WARNING: WHEN USING A HIGH OUTPUT BOOST-
ING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS.
WARNING: REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: DO NOT ATTEMPT TO PUSH OR TOW
THE VEHICLE TO START IT. THE VEHICLE CANNOT
BE STARTED THIS WAY. PUSHING WITH ANOTHER
VEHICLE MAY DAMAGE THE TRANSAXLE OR THE
REAR OF THE VEHICLE.
(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
²Battery cable clamp condition, clean if necessary.
²Frozen battery.
²Clear or bright color test indicator, if equipped.
²Generator drive belt condition and tension.
²Fuel fumes or leakage, correct if necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When using another vehicle as a booster
source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
(3) On disabled vehicle, place gear selector in park
or neutral and set park brake. Turn off all accesso-
ries.
(4) Connect jumper cables to booster battery. RED
clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite
end of cables to touch, electrical arc will result.
Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
jumper cable clamp to engine ground as close to the
ground cable attaching point as possible (Fig. 6).
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - STANDARD PROCEDURE).
(6) Start the engine in the vehicle which has the
booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the dis-
charged battery.
Fig. 5 HOISTING AND JACKING POINTS
1- DRIVE ON LIFT
2 - FRAME CONTACT LIFT (SINGLE POST)
2 - CHASSIS LIFT (NON-AXLE DUAL POST)
2 - OUTBOARD LIFT (DUAL POST)
2 - FLOOR JACK
3 - S.A.E. HOISTING SYMBOLS
RSLUBRICATION & MAINTENANCE0-25
HOISTING (Continued)