Chrysler Voyager 1996-2000 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Generation: NS (Second Generation) Model Years Covered: 1996, 1997, 1998, 1999, 2000 👋 Introduction Market Position Vehicle Segment: Minivan Competitive Analysis Key Competitors: Dodge Grand Caravan, Plymouth Grand Voyager (shared platform), Toyota Sienna, Honda Odyssey, Ford Windstar Key Features Vehicle Platform: Chrysler NS platform (shared with Dodge Caravan/Plymouth Voyager) Vehicle Body Styles: Short wheelbase (Voyager) and Long wheelbase (Grand Voyager) configurations available. Manual Benefit Statement: Empowers owners to make informed decisions about maintenance and repairs, saving on labor costs. 📋 Manual Details Coverage Areas Primary Coverage: North America (US, Canada, Mexico) Regional Variants: Standard US Market, likely includes Canada/Mexico variations where applicable. Page Count Estimated Page Count: Hundreds of pages (exact count not specified, typical for full factory service manuals of this era) Manual Type Type: Factory Service Repair Manual Authenticity: Actual Genuine Factory Service Repair Manual (not a third-party reprint or condensed version). Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Service/Repair, Transmission Service/Repair, Differential/Drive, Axle Chassis: Brake System, Suspension, Steering, Cooling System, Fuel Injection/Fuel System, Emission System, Chassis/Body Electrical And Electronics: Wiring Diagram, Electrical System, Engine Control System Comfort And Convenience: Heater/Air Conditioning, Interior Safety And Restraint: Restraint System Body And Trim: Body/Chassis, Interior, Heater/Air Conditioning, Restraint System Interior Systems: Focus on interior trim, seat mechanisms, and accessory functionality. Procedures Included Maintenance: General Maintenance, Periodic Lubrication Diagnostics And Troubleshooting: Troubleshooting, Advanced troubleshooting guide Repair And Rebuilding: Step-by-step repair procedures for all covered systems, rebuild procedures Diagnostics: Diagnostic procedures for electrical and mechanical systems Tune Up Procedures: Detailed tune-up procedures including spark plug replacement, ignition system checks, fuel system cleaning, and emissions system adjustments. Body Repair: Information on body panel removal/installation, door mechanisms, and basic structural repair. Diagnostic Troubleshooting Guide: Features an advanced troubleshooting guide to help diagnose and correct problems effectively. Technical Depth Depth: Complete factory-level technical information, suitable for professional technicians and experienced DIYers. Diagrams And Illustrations: Includes hundreds of illustrations, drawings, photos, and detailed diagrams for all repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text within the PDF for quick information retrieval. Print Quality Printability: Printable without restriction, individual pages or entire manual. Detail Level: High resolution for clear viewing and printing of all information, diagrams, and photos. Binding Type Binding: Digital Download (Print-on-demand capability) Paper Type Paper Format For Printing: Standard A4/Letter paper ⚙️ Engine Specifications Primary Engine Engine Options 1996-2000: 3.0L V6 (Mitsubishi 6G72), 3.3L V6 (Chrysler EER/EGX), 3.8L V6 (Chrysler L32) Performance Horsepower 3.0L V6: Approx. 150 hp @ 5000 rpm (varies by year/tune) Torque 3.0L V6: Approx. 170 lb-ft @ 3750 rpm (varies by year/tune) Horsepower 3.3L V6: Approx. 158 hp @ 4700 rpm (varies by year/tune) Torque 3.3L V6: Approx. 190 lb-ft @ 3200 rpm (varies by year/tune) Horsepower 3.8L V6: Approx. 166 hp @ 4400 rpm (varies by year/tune) Torque 3.8L V6: Approx. 207 lb-ft @ 3200 rpm (varies by year/tune) Fuel System Fuel Injection: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Options 1996-2000 Engine Codes 3.0L: 6G72 Engine Codes 3.3L: EER, EGX Engine Codes 3.8L: L32 🔧 Transmission Standard Transmission Type Standard: 4-speed Automatic (e.g., 41TE/AE) Optional Transmission Type Optional: None commonly specified for this generation Features Transmission Features: Includes electronic control for shifting and torque converter lock-up. 📐 Dimensions Exterior Wheelbase: Approx. 112.1 inches (2847 mm) Length: Approx. 187.4 inches (4760 mm) (Standard Wheelbase), 194.5 inches (4940 mm) (Long Wheelbase - Grand Voyager) Weights Curb Weight: Varies by configuration, typically 3,800 - 4,200 lbs (1724 - 1905 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: Good (for the driver and passenger in frontal crash tests, based on IIHS/NHTSA data for the era) Active Features ABS: Standard on most models/trims, Anti-lock Braking System Passive Features Airbags: Driver and passenger front airbags standard. Seat Belts: All seating positions equipped with three-point seat belts. Front seat belt pretensioners. 💡 Technology Features Infotainment Audio Systems: Various AM/FM stereo systems with cassette and CD player options. Available premium audio systems. Driver Assistance Cruise Control: Available on most trims. Connectivity Power Features: Power windows, power door locks, available power sliding rear doors, available power liftgate. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-7,500 miles (4,800-12,000 km) or 3-6 months, depending on driving conditions and oil type specified in the manual. Transmission Fluid Change: Recommended every 30,000-60,000 miles (48,000-96,000 km) or as specified by the manual for the specific transmission. Fluid Specifications Engine Oil Type: SAE 5W-30 is common for most engines of this era, but specific viscosity depends on ambient temperature and engine. Consult manual for exact specification (e.g., API SG/SH/SJ rated). Transmission Fluid Type: Chrysler ATF+4 (or equivalent specification fluid, e.g., ATF+3 for earlier versions/compatibility). Coolant Type: Chrysler Long Life Antifreeze/Coolant (HOAT) or equivalent (typically a 50/50 mix with distilled...
Varies by configuration, typically 3,800 - 4,200 lbs (1724 - 1905 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Good (for the driver and passenger in frontal crash tests, based on IIHS/NHTSA data for the era)
Active Features
ABS:
Standard on most models/trims, Anti-lock Braking System
Passive Features
Airbags:
Driver and passenger front airbags standard.
Seat Belts:
All seating positions equipped with three-point seat belts. Front seat belt pretensioners.
💡 Technology Features
Infotainment
Audio Systems:
Various AM/FM stereo systems with cassette and CD player options. Available premium audio systems.
Driver Assistance
Cruise Control:
Available on most trims.
Connectivity
Power Features:
Power windows, power door locks, available power sliding rear doors, available power liftgate.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-7,500 miles (4,800-12,000 km) or 3-6 months, depending on driving conditions and oil type specified in the manual.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles (48,000-96,000 km) or as specified by the manual for the specific transmission.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 is common for most engines of this era, but specific viscosity depends on ambient temperature and engine. Consult manual for exact specification (e.g., API SG/SH/SJ rated).
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification fluid, e.g., ATF+3 for earlier versions/compatibility).
Coolant Type:
Chrysler Long Life Antifreeze/Coolant (HOAT) or equivalent (typically a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, as specified in the manual.
Known Issues
Common Issues Powertrain:
Transmission solenoid failures (especially in 41TE/AE transmissions), rear main seal leaks, intake manifold gasket leaks (3.3L/3.8L).
Common Issues Chassis:
Rattles and squeaks from interior trim and sliding door mechanisms, HVAC blower motor resistor failure, power window motor issues.
Common Issues Electrical:
Instrument cluster failure (especially odometer), power door lock and window switch issues, O2 sensor failures.
Cooling System Issues:
Leaking water pumps, radiator leaks, and thermostat failures are common and covered.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in the early 1980s.
Model Evolution
Generation Ns Context:
The NS Voyager (and its Plymouth/Dodge counterparts) represented the second generation, introducing aerodynamic styling and more refined interiors compared to the first generation.
Production
Assembly Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Consumer Reports ratings varied for this generation, often citing average to below-average reliability for some components. Manual provides detailed repair procedures to address these.
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