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Chrysler Voyager 1996-2000 Service Repair Workshop Manual

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Basic Information Identification Make: Chrysler Model: Voyager Years Covered: 1996, 1997, 1998, 1999, 2000 Codes Platform: Chrysler NS/GS Platform Introduction Market Position Segment: Minivan Target Audience: Families, commercial users requiring passenger transport Competitive Analysis Competitors: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Lumina APV/Trans Sport, Pontiac Montana/Trans Sport Key Features Features: Spacious interior, flexible seating arrangements, front-wheel drive, available Stow 'n Go seating (later models, but platform foundation laid). Manual Details Coverage Areas Regions: North America (primarily US & Canada), potentially European variations Page Count Estimated Page Count: Approx. 1000-1500 pages (typical for comprehensive service manuals of this era) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, engine control systems (ECU/PCM diagnostics and calibration) Transmission: Automatic Transmission (e.g., 41TE, 42LE) mechanical and hydraulic operation, control systems, servicing, and repair Drivetrain: Front-wheel drive components, axles, CV joints, wheel bearings Suspension: Front and rear suspension systems, shock absorbers, struts, control arms, ball joints, sway bars Steering: Power steering system, steering column, tie rods, steering gear/rack Brakes: Front and rear brake systems (disc and drum), hydraulic components, ABS (Anti-lock Braking System) operation and diagnostics Electrical: Battery, charging system (alternator), starting system, lighting system, instrument panel, power windows, power locks, HVAC controls, wiring diagrams HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, component replacement, refrigerant handling (as per regulations) Body: Body panels, doors, latches, hinges, glass, interior trim, exterior trim, bumpers Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement Repair: Engine rebuild procedures, transmission overhaul, brake component replacement, suspension component repair, electrical component diagnosis and replacement, HVAC system repair Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnosis, mechanical system diagnosis Diagnostics: OBD-II (On-Board Diagnostics) procedures, scan tool usage, sensor testing, actuator testing Specifications: Torque specifications, clearance measurements, fluid capacities, electrical specifications, pressure readings Technical Depth Depth: Comprehensive; covers routine maintenance to major component overhauls and in-depth diagnostics. Detail Level: Detailed step-by-step instructions with accompanying diagrams and illustrations. Manual Specifications File Format File Type: PDF Searchable: Typically yes, if properly digitized with OCR. Print Quality Print Readability: Designed for clear viewing on screen and printing, with legible diagrams. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) Engine Specifications Primary Engine Engine Code 1: 3.0L V6 OHV (EGA) Displacement 1: 2972 cc (181 cubic inches) Horsepower 1: Approx. 150-158 hp @ 5000-5200 rpm (varies slightly by year/tune) Torque 1: Approx. 170-175 lb-ft @ 3500-4000 rpm (varies slightly by year/tune) Secondary Engine Engine Code 2: 3.3L V6 OHV (EHD/JED) Displacement 2: 3301 cc (201 cubic inches) Horsepower 2: Approx. 158-180 hp @ 5000-5200 rpm (introduced later in the generation) Torque 2: Approx. 190-206 lb-ft @ 3200-4000 rpm (introduced later in the generation) Performance Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Ignition System: Distributorless Ignition System (DIS) or distributor-based systems Fuel System Fuel Type: Unleaded gasoline (87 octane recommended) Transmission Standard Type 1: 4-speed Automatic Transaxle (e.g., 41TE, 42LE) Optional Type 2: None (automatic was standard for this generation and market) Features Gear Ratios: Specific ratios documented in the manual for each transmission variant Fluid Type: Chrysler ATF+4 (or equivalent compatible fluid for the era, e.g., ATF+3 where specified) Dimensions Exterior Wheelbase: Approx. 112.1 inches (2847 mm) Length: Approx. 189.4 inches (4811 mm) Width: Approx. 72.1 inches (1831 mm) Height: Approx. 67.7 inches (1720 mm) Interior Seating Capacity: Up to 7 passengers (configurations vary) Cargo Cargo Volume Behind 3Rd Row: Approx. 21-26 cubic feet (varies by configuration) Cargo Volume Max: Approx. 140-150 cubic feet (with rear seats removed) Weights Curb Weight: Approx. 3700 - 4000 lbs (1678 - 1814 kg), depending on configuration Towing Capacity: Typically around 2000-3500 lbs (check specific configurations and trailer brake requirements) Safety Features Ratings NHTSA Driver Side Front: Acceptable to Good (depending on specific year and testing protocols) NHTSA Passenger Side Front: Acceptable to Good (depending on specific year and testing protocols) Active Features ABS: Standard or optional Anti-lock Braking System (ABS) on all models Traction Control: Optional traction control system available on some models Passive Features Airbags: Driver and front passenger airbags standard Seat Belts: Three-point seat belts for all seating positions, shoulder belts with retractors Technology Features Infotainment Radio: AM/FM stereo with cassette, optional CD player, and premium sound systems available. Climate Control: Manual or automatic climate control systems available. Driver Assistance Cruise Control: Standard or optional cruise control Keyless Entry: Optional keyless entry and remote key fob systems. Connectivity Auxiliary Ports: N/A (Not a feature of this era) Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 3-6 months (depending on oil type and driving conditions, refer to manual for specifics) Transmission Fluid Change: Typically every 30,000-60,000 miles,...
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Chrysler Voyager 1996-2000 Service Repair Workshop Manual
Basic Information
Identification
Make: Chrysler
Model: Voyager
Years Covered: 1996, 1997, 1998, 1999, 2000
Codes
Platform: Chrysler NS/GS Platform
Introduction
Market Position
Segment: Minivan
Target Audience: Families, commercial users requiring passenger transport
Competitive Analysis
Competitors: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Lumina APV/Trans Sport, Pontiac Montana/Trans Sport
Key Features
Features: Spacious interior, flexible seating arrangements, front-wheel drive, available Stow 'n Go seating (later models, but platform foundation laid).
Manual Details
Coverage Areas
Regions: North America (primarily US & Canada), potentially European variations
Page Count
Estimated Page Count: Approx. 1000-1500 pages (typical for comprehensive service manuals of this era)
Manual Type
Type: Service Repair Workshop Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Powertrain: Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, engine control systems (ECU/PCM diagnostics and calibration)
Transmission: Automatic Transmission (e.g., 41TE, 42LE) mechanical and hydraulic operation, control systems, servicing, and repair
Drivetrain: Front-wheel drive components, axles, CV joints, wheel bearings
Suspension: Front and rear suspension systems, shock absorbers, struts, control arms, ball joints, sway bars
Steering: Power steering system, steering column, tie rods, steering gear/rack
Brakes: Front and rear brake systems (disc and drum), hydraulic components, ABS (Anti-lock Braking System) operation and diagnostics
Electrical: Battery, charging system (alternator), starting system, lighting system, instrument panel, power windows, power locks, HVAC controls, wiring diagrams
HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, component replacement, refrigerant handling (as per regulations)
Body: Body panels, doors, latches, hinges, glass, interior trim, exterior trim, bumpers
Procedures Included
Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement
Repair: Engine rebuild procedures, transmission overhaul, brake component replacement, suspension component repair, electrical component diagnosis and replacement, HVAC system repair
Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnosis, mechanical system diagnosis
Diagnostics: OBD-II (On-Board Diagnostics) procedures, scan tool usage, sensor testing, actuator testing
Specifications: Torque specifications, clearance measurements, fluid capacities, electrical specifications, pressure readings
Technical Depth
Depth: Comprehensive; covers routine maintenance to major component overhauls and in-depth diagnostics.
Detail Level: Detailed step-by-step instructions with accompanying diagrams and illustrations.
Manual Specifications
File Format
File Type: PDF
Searchable: Typically yes, if properly digitized with OCR.
Print Quality
Print Readability: Designed for clear viewing on screen and printing, with legible diagrams.
Binding Type
Binding: N/A (Digital PDF format)
Paper Type
Paper: N/A (Digital PDF format)
Engine Specifications
Primary Engine
Engine Code 1: 3.0L V6 OHV (EGA)
Displacement 1: 2972 cc (181 cubic inches)
Horsepower 1: Approx. 150-158 hp @ 5000-5200 rpm (varies slightly by year/tune)
Torque 1: Approx. 170-175 lb-ft @ 3500-4000 rpm (varies slightly by year/tune)
Secondary Engine
Engine Code 2: 3.3L V6 OHV (EHD/JED)
Displacement 2: 3301 cc (201 cubic inches)
Horsepower 2: Approx. 158-180 hp @ 5000-5200 rpm (introduced later in the generation)
Torque 2: Approx. 190-206 lb-ft @ 3200-4000 rpm (introduced later in the generation)
Performance
Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI)
Ignition System: Distributorless Ignition System (DIS) or distributor-based systems
Fuel System
Fuel Type: Unleaded gasoline (87 octane recommended)
Transmission
Standard
Type 1: 4-speed Automatic Transaxle (e.g., 41TE, 42LE)
Optional
Type 2: None (automatic was standard for this generation and market)
Features
Gear Ratios: Specific ratios documented in the manual for each transmission variant
Fluid Type: Chrysler ATF+4 (or equivalent compatible fluid for the era, e.g., ATF+3 where specified)
Dimensions
Exterior
Wheelbase: Approx. 112.1 inches (2847 mm)
Length: Approx. 189.4 inches (4811 mm)
Width: Approx. 72.1 inches (1831 mm)
Height: Approx. 67.7 inches (1720 mm)
Interior
Seating Capacity: Up to 7 passengers (configurations vary)
Cargo
Cargo Volume Behind 3Rd Row: Approx. 21-26 cubic feet (varies by configuration)
Cargo Volume Max: Approx. 140-150 cubic feet (with rear seats removed)
Weights
Curb Weight: Approx. 3700 - 4000 lbs (1678 - 1814 kg), depending on configuration
Towing Capacity: Typically around 2000-3500 lbs (check specific configurations and trailer brake requirements)
Safety Features
Ratings
NHTSA Driver Side Front: Acceptable to Good (depending on specific year and testing protocols)
NHTSA Passenger Side Front: Acceptable to Good (depending on specific year and testing protocols)
Active Features
ABS: Standard or optional Anti-lock Braking System (ABS) on all models
Traction Control: Optional traction control system available on some models
Passive Features
Airbags: Driver and front passenger airbags standard
Seat Belts: Three-point seat belts for all seating positions, shoulder belts with retractors
Technology Features
Infotainment
Radio: AM/FM stereo with cassette, optional CD player, and premium sound systems available.
Climate Control: Manual or automatic climate control systems available.
Driver Assistance
Cruise Control: Standard or optional cruise control
Keyless Entry: Optional keyless entry and remote key fob systems.
Connectivity
Auxiliary Ports: N/A (Not a feature of this era)
Maintenance
Service Intervals
Oil Change Interval: Every 3,000-7,500 miles or 3-6 months (depending on oil type and driving conditions, refer to manual for specifics)
Transmission Fluid Change: Typically every 30,000-60,000 miles, or as indicated by service bulletins
Coolant Flush: Every 30,000-50,000 miles or 2-3 years
Spark Plug Replacement: Every 60,000-100,000 miles for platinum-tipped plugs (check manual)
Fluid Specifications
Engine Oil: SAE 5W-30 (API Certified, refer to manual for exact viscosity and API service category)
Coolant: Chrysler Long Life Antifreeze/Coolant (OAT - Organic Additive Technology) or equivalent, typically a 50/50 mix with distilled water
Brake Fluid: DOT 3 or DOT 4 Hydraulic Brake Fluid
Known Issues
Common Problems: Transmission solenoid failures, EGR valve issues, coolant leaks (intake manifold gaskets, heater core), power window regulator failures, rear axle bearing wear, power steering pump leaks, AC system leaks.
Common Problems Detail: The 4-speed automatic transmissions are known for potential solenoid pack issues and torque converter clutch (TCC) problems. The 3.0L Mitsubishi engine can be prone to intake manifold gasket leaks, affecting cooling and emissions.
Vehicle History
Brand Heritage
Heritage: Chrysler has a long history of innovation in vehicle design, particularly with the minivan segment pioneered by the Dodge Caravan/Plymouth Voyager.
Model Evolution
Generation: Second Generation Chrysler Voyager (GS Platform)
Redesign: This generation, introduced for the 1996 model year, featured a significant redesign with a more aerodynamic exterior, improved interior ergonomics, and updated powertrains.
Production
Manufacturing Location: Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years: 1996-2000 (for this specific manual's coverage)
Awards & Recognition
Recognitions
Car And Driver 10Best: The first generation Voyager/Caravan/Voyager was a repeated recipient of Car and Driver's 10Best list, establishing the minivan segment's viability.
Model Reputation: Known for its practicality, spaciousness, and value proposition within the minivan market.
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