Chrysler Voyager 1996-2005 Factory Service Repair Manual

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Basic Information Identification Make: Chrysler Model: Voyager Model Variant: This manual covers the Chrysler Voyager minivan. Codes Platform: NS/GS (Second Generation) Introduction Market Position Segment: Mid-size minivan segment. A direct competitor to vehicles like the Honda Odyssey, Toyota Sienna, and Ford Windstar. Competitive Analysis Key Strengths: Known for its flexible seating configurations, Stow 'n Go (though introduced later than 1996, the platform shares DNA), and often more powerful V6 engine options compared to some rivals of its era. Key Features Minivan Design: Sliding rear doors, multiple rows of seating, designed for family transport and cargo hauling. Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Pages: Approximately 2000+ pages (typical for comprehensive factory service manuals of this era) Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanics: Detailed coverage of engine assembly, disassembly, inspection, and repair for all applicable engine variants. Engine Management: Diagnosis and repair of fuel injection, ignition system, emissions control, and powertrain control modules (PCM). Transmission Manual: Service and repair procedures for manual transmissions (if applicable to certain trims). Transmission Automatic: Comprehensive coverage for automatic transmission (e.g., A604, 41TE, 42LE) diagnostics, overhaul, and service. Drivetrain: Front-wheel drive (FWD) axle shafts, constant velocity (CV) joints, and differential service. Brakes: Front and rear brake system diagnosis, service, repair, including ABS (Anti-lock Braking System) components. Suspension: Front and rear suspension components, alignment, shock absorbers, struts, control arms, and sway bars. Steering: Power steering system diagnosis, repair, steering rack, tie rods, and power steering pump service. Body And Frame: Body panel repair, door mechanisms, interior trim, glass replacement, and structural component service. Electrical System: Complete wiring diagrams, circuit descriptions, component testing, and repair for all electrical systems. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, refrigerant handling, component replacement, and performance testing. Restraint Systems: Airbag system diagnosis, service, and safety precautions. Seat belt mechanisms. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, coolant flush, and lubrication schedules. Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides, and fault code interpretation. Component Replacement: Step-by-step instructions for replacing major components like engines, transmissions, alternators, starters, etc. Diagnostic Procedures: Detailed procedures for using diagnostic tools, interpreting scan data, and performing electrical tests. Rebuilds: Instructions for complete engine and transmission overhauls, including specifications for machining and assembly. Wiring Diagrams: Extensive and detailed wiring schematics for all electrical systems. Technical Depth Depth: Comprehensive, covering everything from basic preventive maintenance to complex engine and transmission rebuilds and advanced electrical diagnostics. Manual Specifications File Format Quality: High-resolution PDF, ensuring clear text and diagrams. Typically searchable. Print Quality Printable: Designed to be printable for workshop use, allowing users to print specific sections as needed. Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper: N/A (Digital PDF) Engine Specifications Primary Engine Engine 1 Variant: 2.4L DOHC Inline-4 (771, G4CS) Engine 1 Displacement: 2.4 Liters (2429 cc) Engine 1 Horsepower: Approx. 150 hp @ 5800 rpm Engine 1 Torque: Approx. 165 lb-ft @ 4400 rpm Secondary Engine Engine 2 Variant: 3.0L SOHC V6 (EGA, EGN, 6G72) Engine 2 Displacement: 3.0 Liters (2972 cc) Engine 2 Horsepower: Approx. 150-158 hp @ 5200-5250 rpm Engine 2 Torque: Approx. 180-185 lb-ft @ 3300-4500 rpm Tertiary Engine Engine 3 Variant: 3.3L SOHC V6 (U11) Engine 3 Displacement: 3.3 Liters (3301 cc) Engine 3 Horsepower: Approx. 170-180 hp @ 5000-5200 rpm Engine 3 Torque: Approx. 195-205 lb-ft @ 3000-3600 rpm Quad Engine Engine 4 Variant: 3.8L SOHC V6 (EWG, EWE, 90-degree V6) Engine 4 Displacement: 3.8 Liters (3778 cc) Engine 4 Horsepower: Approx. 180 hp @ 4700 rpm (later models up to 215 hp) Engine 4 Torque: Approx. 240 lb-ft @ 3400 rpm (later models up to 245 lb-ft) Fuel System Injection Type: Multi-point Fuel Injection (MPI) or Sequential Fuel Injection (SFI). Fuel Type: Unleaded gasoline. Octane rating recommendations typically 87 AKI. Transmission Standard Transmission Standard Type: Automatic (FWD specific) Transmission Standard Models: A604 (4-speed Automatic), 41TE/42LE (4-speed Automatic with Electronic Overdrive) Optional Transmission Optional Type: Manual Transmission (less common, often specific to early or base models, e.g., Getrag 283 manual) Features Transmission Features: Electronic shift control, torque converter lock-up, overdrive gear for fuel efficiency. Some models feature Chrysler's 'AutoStick' manual shifting mode. Dimensions Exterior Wheelbase: Approximately 112.1 inches (2847 mm) Length: Approximately 186.1 - 189.7 inches (4727 - 4818 mm) depending on model year and trim Width: Approximately 72.0 - 72.1 inches (1829 - 1831 mm) Height: Approximately 67.1 - 67.9 inches (1704 - 1725 mm) Weights Curb Weight: Ranges from approximately 3,700 lbs (1678 kg) to over 4,300 lbs (1950 kg) depending on engine and configuration. Gross Vehicle Weight Rating: Typically around 5,750 lbs (2608 kg) Cargo Cargo Volume Max: Over 150 cubic feet (4247 liters) with rear seats...

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Art.-Nr: 69072

Sammlungen: ALL Chrysler Marine

Verfügbarkeit: Auf Lager

Stichworte: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Car Chrysler Marine Misc Outboard Engines Voyager

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Beschreibung

Basic Information
Identification
Make:	Chrysler
Model:	Voyager
Model Variant:	This manual covers the Chrysler Voyager minivan.
Codes
Platform:	NS/GS (Second Generation)

Introduction
Market Position
Segment:	Mid-size minivan segment. A direct competitor to vehicles like the Honda Odyssey, Toyota Sienna, and Ford Windstar.
Competitive Analysis
Key Strengths:	Known for its flexible seating configurations, Stow 'n Go (though introduced later than 1996, the platform shares DNA), and often more powerful V6 engine options compared to some rivals of its era.
Key Features
Minivan Design:	Sliding rear doors, multiple rows of seating, designed for family transport and cargo hauling.

Manual Details
Coverage Areas
Years Covered:	1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Page Count
Estimated Pages:	Approximately 2000+ pages (typical for comprehensive factory service manuals of this era)
Manual Type
Type:	Factory Service Repair Manual (FSM)
Language
Language:	English
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanics:	Detailed coverage of engine assembly, disassembly, inspection, and repair for all applicable engine variants.
Engine Management:	Diagnosis and repair of fuel injection, ignition system, emissions control, and powertrain control modules (PCM).
Transmission Manual:	Service and repair procedures for manual transmissions (if applicable to certain trims).
Transmission Automatic:	Comprehensive coverage for automatic transmission (e.g., A604, 41TE, 42LE) diagnostics, overhaul, and service.
Drivetrain:	Front-wheel drive (FWD) axle shafts, constant velocity (CV) joints, and differential service.
Brakes:	Front and rear brake system diagnosis, service, repair, including ABS (Anti-lock Braking System) components.
Suspension:	Front and rear suspension components, alignment, shock absorbers, struts, control arms, and sway bars.
Steering:	Power steering system diagnosis, repair, steering rack, tie rods, and power steering pump service.
Body And Frame:	Body panel repair, door mechanisms, interior trim, glass replacement, and structural component service.
Electrical System:	Complete wiring diagrams, circuit descriptions, component testing, and repair for all electrical systems.
HVAC:	Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, refrigerant handling, component replacement, and performance testing.
Restraint Systems:	Airbag system diagnosis, service, and safety precautions. Seat belt mechanisms.
Procedures Included
Routine Maintenance:	Oil changes, filter replacements, spark plug service, coolant flush, and lubrication schedules.
Troubleshooting:	Diagnostic charts, symptom-based troubleshooting guides, and fault code interpretation.
Component Replacement:	Step-by-step instructions for replacing major components like engines, transmissions, alternators, starters, etc.
Diagnostic Procedures:	Detailed procedures for using diagnostic tools, interpreting scan data, and performing electrical tests.
Rebuilds:	Instructions for complete engine and transmission overhauls, including specifications for machining and assembly.
Wiring Diagrams:	Extensive and detailed wiring schematics for all electrical systems.
Technical Depth
Depth:	Comprehensive, covering everything from basic preventive maintenance to complex engine and transmission rebuilds and advanced electrical diagnostics.

Manual Specifications
File Format
Quality:	High-resolution PDF, ensuring clear text and diagrams. Typically searchable.
Print Quality
Printable:	Designed to be printable for workshop use, allowing users to print specific sections as needed.
Binding Type
Digital Binding:	N/A (Digital PDF)
Paper Type
Digital Paper:	N/A (Digital PDF)

Engine Specifications
Primary Engine
Engine 1 Variant:	2.4L DOHC Inline-4 (771, G4CS)
Engine 1 Displacement:	2.4 Liters (2429 cc)
Engine 1 Horsepower:	Approx. 150 hp @ 5800 rpm
Engine 1 Torque:	Approx. 165 lb-ft @ 4400 rpm
Secondary Engine
Engine 2 Variant:	3.0L SOHC V6 (EGA, EGN, 6G72)
Engine 2 Displacement:	3.0 Liters (2972 cc)
Engine 2 Horsepower:	Approx. 150-158 hp @ 5200-5250 rpm
Engine 2 Torque:	Approx. 180-185 lb-ft @ 3300-4500 rpm
Tertiary Engine
Engine 3 Variant:	3.3L SOHC V6 (U11)
Engine 3 Displacement:	3.3 Liters (3301 cc)
Engine 3 Horsepower:	Approx. 170-180 hp @ 5000-5200 rpm
Engine 3 Torque:	Approx. 195-205 lb-ft @ 3000-3600 rpm
Quad Engine
Engine 4 Variant:	3.8L SOHC V6 (EWG, EWE, 90-degree V6)
Engine 4 Displacement:	3.8 Liters (3778 cc)
Engine 4 Horsepower:	Approx. 180 hp @ 4700 rpm (later models up to 215 hp)
Engine 4 Torque:	Approx. 240 lb-ft @ 3400 rpm (later models up to 245 lb-ft)
Fuel System
Injection Type:	Multi-point Fuel Injection (MPI) or Sequential Fuel Injection (SFI).
Fuel Type:	Unleaded gasoline. Octane rating recommendations typically 87 AKI.

Transmission
Standard
Transmission Standard Type:	Automatic (FWD specific)
Transmission Standard Models:	A604 (4-speed Automatic), 41TE/42LE (4-speed Automatic with Electronic Overdrive)
Optional
Transmission Optional Type:	Manual Transmission (less common, often specific to early or base models, e.g., Getrag 283 manual)
Features
Transmission Features:	Electronic shift control, torque converter lock-up, overdrive gear for fuel efficiency. Some models feature Chrysler's 'AutoStick' manual shifting mode.

Dimensions
Exterior
Wheelbase:	Approximately 112.1 inches (2847 mm)
Length:	Approximately 186.1 - 189.7 inches (4727 - 4818 mm) depending on model year and trim
Width:	Approximately 72.0 - 72.1 inches (1829 - 1831 mm)
Height:	Approximately 67.1 - 67.9 inches (1704 - 1725 mm)
Weights
Curb Weight:	Ranges from approximately 3,700 lbs (1678 kg) to over 4,300 lbs (1950 kg) depending on engine and configuration.
Gross Vehicle Weight Rating:	Typically around 5,750 lbs (2608 kg)
Cargo
Cargo Volume Max:	Over 150 cubic feet (4247 liters) with rear seats removed/folded.

Safety Features
Ratings
NHTSA Front Impact:	Mixed results across years; typically 4-star driver, 3-star passenger in frontal impact (1996-1999 models).
NHTSA Side Impact:	Varies by year and equipment, often 3-star or 4-star.
Active Features
ABS:	Anti-lock Braking System (ABS) available, often standard on higher trims or later models.
Traction Control:	Traction control system available on some V6 models, particularly later years.
Passive Features
Airbags:	Driver and front passenger airbags standard. Side airbags were an option on later models.
Seatbelts:	Three-point seatbelts for all seating positions, with pretensioners for front occupants.

Technology Features
Infotainment
Audio Systems:	Various cassette and CD players, often with optional premium sound systems. Early models might have analog controls, later ones start to see digital displays.
Navigation:	Early factory navigation systems were available on higher trims in the later years of this generation, often DVD-based.
Driver Assistance
Cruise Control:	Standard cruise control on most models. Advanced driver-assistance systems (ADAS) were not common in this era.
Connectivity
Power Features:	Power windows, power door locks, power sliding doors (optional), and power liftgate (optional on some later models) were available.

Maintenance
Service Intervals
Oil Change Interval:	Typically every 3,000-7,500 miles (4,800-12,000 km) or 6-12 months, depending on driving conditions and oil type used (consult specific manual for exact recommendation based on oil used).
Transmission Fluid Change:	Recommended every 30,000-60,000 miles (48,000-96,000 km), depending on driving habits.
Coolant Flush:	Typically every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.
Spark Plugs:	Replace spark plugs every 30,000-100,000 miles (48,000-160,000 km) depending on spark plug type (copper, platinum, iridium).
Fluid Specifications
Engine Oil Spec:	SAE 5W-30 is common for most engines, but 5W-20 or 10W-30 might be specified for some. Always verify with the manual. API Service Classification SN or higher recommended for newer oils.
Transmission Fluid Spec:	Chrysler ATF+4 (or equivalent specification) is typically required for automatic transmissions.
Coolant Spec:	Chrysler Antifreeze/Coolant (Mopar OAT or HOAT type) or equivalent. Typically a 50/50 mix with distilled water.
Known Issues
Transmission Problems:	Early automatic transmissions (A604) can be prone to solenoid issues, torque converter shudder, and fluid leaks. Regular fluid changes are critical.
Engine Problems:	Head gasket leaks (especially on 3.3L and 3.8L V6), oil cooler leaks, and intake manifold gasket leaks are common. Spark plug blow-out on some V6 engines is also a known issue.
Electrical Issues:	Faulty power window regulators, HVAC blower motor failures, and intermittent electrical gremlins are reported.
Suspension Wear:	Sway bar links, ball joints, and tie rod ends can wear out prematurely due to the vehicle's weight.

Vehicle History
Brand Heritage
Chrysler Minivan Pioneering:	Chrysler is widely credited with inventing the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. This manual covers the evolution of that successful formula.
Model Evolution
Generation Details:	This 1996-2005 period covers the second generation (NS, 1996-2000) and the facelifted third generation (GS, 2001-2007) of the Chrysler Voyager platform (shared with Dodge Grand Caravan and Plymouth Grand Voyager/Voyager).
Key Changes Gs Generation:	The GS generation (2001-2007) introduced a more modern exterior and interior design, improved safety features, and powertrain updates, including the introduction of the 3.8L V6 as a dominant option.
Production
Manufacturing Locations:	Primarily manufactured in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.
Global Availability:	The Voyager was sold globally, often under different names like Chrysler Grand Voyager in Europe.

Awards & Recognition
Recognitions
Car And Driver 10Best:	Chrysler minivans, including models derived from this platform, frequently appeared on Car and Driver's '10Best' list during the 1990s, underscoring their segment leadership.
Ratings
Consumer Reports Reliability:	Reliability ratings varied by year and specific components. The manual is essential for understanding how to maintain these vehicles to mitigate common issues.