Chrysler Voyager 1996 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 1996 Body Style: Minivan Codes Platform Code: NS (Second Generation) 👋 Introduction Market Position Positioning: The Chrysler Voyager (and its Dodge Caravan and Plymouth Voyager siblings) was a segment-defining minivan, offering practicality and family-friendly features. This era represented a mature design in the minivan market. Competitive Analysis Competitors: Dominated the North American minivan segment against competitors like the Ford Windstar, Honda Odyssey (first generation), and Chevrolet Lumina APV/Venture. Key Features Family Focus: Designed for maximum passenger and cargo capacity, sliding doors, flexible seating arrangements. Powertrain Options: Offered robust V6 engines known for their torque and towing capability, suitable for family hauling. Manual Value Utility: Essential for owners and independent repair shops to perform accurate diagnostics, maintenance, and repairs, saving on dealership costs. 📋 Manual Details Coverage Areas Primary Coverage: Complete factory service and repair procedures for the 1996 Chrysler Voyager. Trim Levels Covered: All trim levels (e.g., SE, LE, LX, ES - specific to regional markets). Page Count Estimated Page Count: 1500-2000+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Print (original factory publication - may be scanned/reproduced digitally). 📖 Manual Coverage Systems Covered Powertrain: Engine, fuel system, exhaust system, transmission (automatic and possibly manual), drivetrain, cooling system, lubrication system. Chassis: Suspension (front and rear), steering system, braking system (including ABS), wheels and tires. Electrical: Wiring diagrams, lighting, power distribution, ignition system, starting system, charging system, battery, instrumentation, body control modules, comfort and convenience systems. Body: Exterior body panels, interior trim, doors, windows, glass, seats, roof systems, bumpers. HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair. Safety Features: Airbag system (SRS) diagnosis and repair, seat belts. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and changes, belt inspections and replacement, spark plug service. Diagnostics Troubleshooting: Step-by-step diagnostic charts, symptom analysis, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing. Repair Rebuild: Detailed instructions for disassembly, inspection, repair, and reassembly of all major components and systems. Specifications Tolerances: Precise measurements, torque specifications, alignment angles, wear limits. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, electrical system troubleshooting, and body repair. 📊 Manual Specifications File Format Digital Format Description: If offered digitally, typically PDF format. High resolution scans are preferred for clarity. Searchable text is a significant advantage. Print Quality Print Quality Description: Original factory manuals are high quality. Reproductions should aim for clear print, legible diagrams, and durable paper. Binding Type Binding Type Description: Originals are typically perfect bound or spiral bound. Reproductions may vary. Paper Type Paper Type Description: Originals use durable, often slightly coated paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Common: 3.0L V6 (Mitsubishi 6G72 SOHC) Engine Displacement 3.0: 2972 cc (181.4 ci) Engine Bore Stroke 3.0: 91.1 mm x 76.0 mm Engine Compression Ratio 3.0: 8.9:1 Engine Horsepower 3.0: 140-141 hp @ 4800-4900 rpm Engine Torque 3.0: 170-174 lb-ft @ 3600-3700 rpm Secondary Engine Engine Code Common: 3.3L V6 (Chrysler EDB SOHC) Engine Displacement 3.3: 3301 cc (201.5 ci) Engine Bore Stroke 3.3: 93.0 mm x 81.0 mm Engine Compression Ratio 3.3: 8.9:1 Engine Horsepower 3.3: 156 hp @ 4800 rpm Engine Torque 3.3: 190 lb-ft @ 3600 rpm Tertiary Engine Engine Code Common: 3.8L V6 (Chrysler EGA SOHC) Engine Displacement 3.8: 3778 cc (230.5 ci) Engine Bore Stroke 3.8: 96.0 mm x 86.0 mm Engine Compression Ratio 3.8: 8.9:1 Engine Horsepower 3.8: 166 hp @ 4500 rpm Engine Torque 3.8: 215 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended, higher octane for improved performance possible) 🔧 Transmission Standard Type Standard: 4-speed Automatic (A604/41TE - Ultradrive/AutoStick) Optional Type Optional: No manual transmission typically offered on Voyager models for this year in North America. Features Transmission Control: Electronic control with adaptive shift logic. Transmission Fluid Type: ATF+4 (or equivalent specification from manual - check for Mopar ATF+3, which was standard and later updated to ATF+4 by Chrysler). 📐 Dimensions Exterior Wheelbase: 113.0 inches (2870 mm) Length: 177.1 - 183.1 inches (4498 - 4651 mm) depending on configuration Width: 72.1 inches (1831 mm) Height: 66.6 inches (1692 mm) Weights Curb Weight Range: Approx. 3700 - 4100 lbs (1680 - 1860 kg) depending on engine and configuration. Cargo Cargo Volume Behind 3Rd Row: Varies by configuration, typically around 30-40 cubic feet. Cargo Volume Max: Over 140 cubic feet with rear seats removed. 🛡️ Safety Features Ratings NHTSA Front Driver Impact: Likely 4-star rating (check specific year/testing data). NHTSA Front Passenger Impact: Likely 4-star rating (check specific year/testing data). IIHS Crash Test Performance: Check specific IIHS reports for this generation. Minivans of this era often had mixed results. Active Features ABS: Anti-lock Braking System (ABS) typically optional or...
The Chrysler Voyager (and its Dodge Caravan and Plymouth Voyager siblings) was a segment-defining minivan, offering practicality and family-friendly features. This era represented a mature design in the minivan market.
Competitive Analysis
Competitors:
Dominated the North American minivan segment against competitors like the Ford Windstar, Honda Odyssey (first generation), and Chevrolet Lumina APV/Venture.
Key Features
Family Focus:
Designed for maximum passenger and cargo capacity, sliding doors, flexible seating arrangements.
Powertrain Options:
Offered robust V6 engines known for their torque and towing capability, suitable for family hauling.
Manual Value
Utility:
Essential for owners and independent repair shops to perform accurate diagnostics, maintenance, and repairs, saving on dealership costs.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete factory service and repair procedures for the 1996 Chrysler Voyager.
Trim Levels Covered:
All trim levels (e.g., SE, LE, LX, ES - specific to regional markets).
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Print (original factory publication - may be scanned/reproduced digitally).
Suspension (front and rear), steering system, braking system (including ABS), wheels and tires.
Electrical:
Wiring diagrams, lighting, power distribution, ignition system, starting system, charging system, battery, instrumentation, body control modules, comfort and convenience systems.
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, electrical system troubleshooting, and body repair.
📊 Manual Specifications
File Format
Digital Format Description:
If offered digitally, typically PDF format. High resolution scans are preferred for clarity. Searchable text is a significant advantage.
Print Quality
Print Quality Description:
Original factory manuals are high quality. Reproductions should aim for clear print, legible diagrams, and durable paper.
Binding Type
Binding Type Description:
Originals are typically perfect bound or spiral bound. Reproductions may vary.
Paper Type
Paper Type Description:
Originals use durable, often slightly coated paper suitable for workshop environments.
Approx. 3700 - 4100 lbs (1680 - 1860 kg) depending on engine and configuration.
Cargo
Cargo Volume Behind 3Rd Row:
Varies by configuration, typically around 30-40 cubic feet.
Cargo Volume Max:
Over 140 cubic feet with rear seats removed.
🛡️ Safety Features
Ratings
NHTSA Front Driver Impact:
Likely 4-star rating (check specific year/testing data).
NHTSA Front Passenger Impact:
Likely 4-star rating (check specific year/testing data).
IIHS Crash Test Performance:
Check specific IIHS reports for this generation. Minivans of this era often had mixed results.
Active Features
ABS:
Anti-lock Braking System (ABS) typically optional or standard on higher trims.
Traction Control:
Traction control system (TCS) became available or standard on some models in this period.
Passive Features
Airbags:
Driver and passenger front airbags (SRS).
Seat Belts:
Three-point seat belts for all occupants, with front seat belt pretensioners.
Child Safety:
Rear door child safety locks, LATCH system may not be standard (check specifics).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette or CD player. Speaker configurations varied by trim level.
Climate Control:
Manual or optional automatic climate control systems.
Driver Assistance
Cruise Control:
Standard or optional cruise control.
Keyless Entry:
Optional keyless entry system.
Connectivity
Wiring Diagrams:
Comprehensive wiring diagrams are a key feature of the manual, essential for diagnosing electrical faults.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 3-6 months, depending on driving conditions (check manual for severe vs. normal service).
Engine Coolant Change:
Initial fill may last longer, but typically recommended every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-3 years.
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-4 years, depending on use (heavy use requires more frequent service).
Spark Plug Replacement:
Around 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (platinum/iridium offer longer life).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40, API Service SG or SH (check manual for specific recommendations).
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) for 3.0L, 5.0 quarts (4.7 liters) for 3.3L/3.8L (with filter change).
Coolant Type:
Mopar Antifreeze/Coolant (50/50 mix with distilled water) or equivalent HOAT coolant.
Power Steering Fluid:
Mopar Power Steering Fluid or Dexron III ATF.
Known Issues
Transmission Issues:
Early 41TE transmissions could be prone to solenoid issues, torque converter shudder, or hard shifting if not properly maintained. Fluid and filter changes are critical.
Head Gaskets:
Some V6 engines, particularly the 3.8L EGH, could be susceptible to head gasket failures, often indicated by coolant loss or white smoke from the exhaust.
Power Window Motors:
Window regulators and motors are common wear items, especially on sliding doors.
Climate Control Blend Doors:
Actuator motors for HVAC blend doors can fail, leading to incorrect air temperature or airflow direction.
Suspension Components:
Wear in ball joints, tie rod ends, and bushings can lead to poor handling and steering issues over time.
📚 Vehicle History
Brand Heritage
Chrysler Legacy:
Chrysler has a long history in automotive manufacturing, particularly known for its innovation in segment creation, like the minivan.
Model Evolution
Generation Ns:
The 1996 model is part of the second generation (NS) of the Chrysler minivans, introduced for the 1996 model year. This generation brought significant styling and mechanical updates.
Design Updates:
Key changes for the NS generation included more aerodynamic styling, a redesigned interior, and improvements to safety and handling.
Production
Production Plants:
Primarily produced in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.
Production Years:
The NS generation ran from 1996 to 2000.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Chrysler minivans were frequent recipients of Car and Driver's '10Best' list in earlier iterations, establishing their market dominance and quality perception.
Ratings
Consumer Reports Reliability:
Reliability ratings from this era can vary. The manual is crucial for understanding how to maintain these vehicles to mitigate common wear-and-tear issues.
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