wheel 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)

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.
2 INTRODUCTIONRS
BODY CODE PLATE (Continued)

POSITION INTERPRETATION CODE = DESCRIPTION
6 Series2 = 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 Style1 = Van - Caravan C/V
3 = Extended Van - Grand Caravan C/V
4 = Extended Wagon - Grand Caravan/Town & Country
5 = Wagon - Caravan, Voyager, Town & Country
7 - Export Body Style1 = 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- Sales Code -
CYX Less AS8)
7 = Commercial Van - Short Wheelbase (with Sales Code -
AS8)
8 = Commercial Van-Long Wheelbase (H - Series with Sales
Code - CYX)
9 = Commercial Van - Long Wheelbase (P - Series with
Sales Code - CYX)
8 EngineB = 2.4L I4 Cyl. 16-Valve Gasoline DOHC (MPI)
E = 3.3L V6 Cyl. OHV Flex Fuel
L = 3.8L V6 Cyl. Gasoline (SMPI)
R = 3.3L V6 Cyl. OHV Gasoline
5 = 2.8L I4 Cyl. Turbo Diesel
7 = 2.5L I4 Cyl. 16 Valve Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 5 = 2005
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)

²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
API CERTIFICATION AND LICENSE SYMBOL
Use an engine oil that is API Certified (GF-3) and
Licensed to display the certification mark (Fig. 2).
MOPARtprovides engine oils that meet or exceed,
Material Standard MS-6395 requirement.
SAE VISCOSITY
SAE 5W-20 and SAE 5W-30 engine oils are rec-
ommended for all operating temperatures.
These engine oils are designed to improve low
temperature starting and vehicle fuel economy.
Refer to the engine oil filler cap for the pre-
ferred engine oil viscosity grade for each vehi-
cle (Fig. 3).SAE viscosity grades are used to specify
the correct viscosity oil for an engine. Use only Multi-
Viscosity oils such as SAE 5W-20 or 5W-30. These
are specified with a dual SAE viscosity grade which
indicates the cold (5W) to hot (20, 30) temperature
performance range of the oil.
CONTAINER IDENTIFICATION
The Engine Oil Certificarion Mark was developed
and trademarked by the API to refer customers to
those engine oils preferred by the automobile manu-
facturers. This symbol means that the oil has been
certified and licensed by the American Petroleum
Institute (API). This certification mark will only be
found on the front of the oil containers. Those oilsthat do not display the ªMarkº on the front of the
container should not be used (Fig. 2).
DiamlerChrysler only recommends API Certified
engine oils that meet the requirements of Material
Standard MS-6395. Use Mopar or an equivalent oil
meeting the specification MS-6395.
SYNTHETIC ENGINE OILS
There are a number of engine oils being promoted
as either synthetic or semi-synthetic. If you chose to
use such a product, useonlythose oils that are cer-
tified by the American Petroleum Institute (API) to
display the ªCertification Markº and show SAE vis-
cosity grade recommended for each vehicle. Follow
the service schedule that describes your driving type.
ENGINE OIL ADDITIVES/SUPPLEMENTS
The manufacturerdoes not recommendthe addi-
tion of any engine oil additives/supplements to the
specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil perfor-
mance. Engine oil additives/supplements should not
be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and
can degrade emission components. Additives can con-
tain undesirable materials that harm the long term
durability of engines by:
²Increasing the level of Phosphorus and Sulfur in
the engine oil. The API Certified Engine Oils control
the Phosphorus and Sulfur contents of the oil to lev-
els that reduce the contamination effect on the vehi-
cles emission control system.
²Altering the viscosity characteristics of the
engine oil so that it no longer meets the require-
ments of the specified viscosity grade.
²Creating potential for an undesirable additive
compatibility interaction in the engine crankcase.
The engine oils contain a performance additive sys-
tem carefully developed to optimize the oils perfor-
mance in the engine. The addition of supplements
may cause the oil to thicken prematurely, cause
excessive deposit build up and potentially shorten
engine life.
AXLE LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-
90.
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
Fig. 2 API Certification Mark
Fig. 3 5W-30 Oil Filler Cap
0 - 2 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

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 theradiator 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.
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.
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-3
FLUID TYPES (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.
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)