Chrysler Voyager 1996-2003 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Codes Platform Code: NS/GS (Second Generation) 👋 Introduction Market Position Segment: Mid-size Minivan Competitive Analysis Competitors: Ford Windstar, Toyota Sienna, Honda Odyssey, Chevrolet Venture/Silhouette/Trans Sport. Key Features Vehicle Highlights: Spacious interior, flexible seating configurations, comfortable ride, availability of all-wheel drive on some models. Manual Value Proposition Benefit To Owner: Empowers owners and independent repair shops with the technical knowledge to perform maintenance, diagnostics, and repairs efficiently and correctly, saving time and money. 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Comprehensive engine diagnostics, overhaul procedures, timing belt replacement, cooling system, lubrication system, fuel delivery, emissions control systems. Transmission Mechanical: Automatic transmission (e.g., 42LE, 41TE) overhaul, repair, fluid service, torque converter replacement, electronic control unit (ECU) diagnostics. Brakes: Hydraulic system, brake fluid service, ABS diagnostics and repair, caliper and rotor replacement, parking brake adjustment. Suspension Steering: Front and rear suspension components, struts, shocks, control arms, ball joints, power steering system, steering rack, alignment procedures. Electrical Electronics: Wiring diagrams, charging system (alternator, battery), starting system, ignition system, lighting, power windows, power locks, interior electronics, fuse and relay identification, diagnostic trouble codes (DTCs). Body Chassis: Body panel repair, door mechanisms, interior trim removal, glass replacement, underbody components, chassis lubrication. HVAC: Air conditioning system service, refrigerant handling, heater core replacement, blower motor, climate control system diagnostics. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC interpretation. Repair Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Special Tools: Identification and usage instructions for specialized tools required for specific repairs. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds; includes detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Quality: High-resolution scans, searchable text, clear diagrams and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 2.4L DOHC I4 (150 hp @ 5,200 rpm, 175 lb-ft @ 3,800 rpm) Engine 2: 3.0L SOHC V6 (150-158 hp @ 5,200-5,400 rpm, 180-190 lb-ft @ 3,600-4,000 rpm) Engine 3: 3.3L SOHC V6 (180 hp @ 5,200 rpm, 210 lb-ft @ 3,600 rpm) - Introduced later in the generation Performance Horsepower Range: 150-180 hp Torque Range: 175-210 lb-ft Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Codes Common Engine Codes: EDZ (2.4L I4), EAT (3.0L V6), EHB (3.3L V6) Cooling System Coolant Capacity: Approx. 9.5 quarts (9.0 L) 🔧 Transmission Standard Transmission Standard: 4-Speed Automatic Optional Transmission Optional: All-Wheel Drive (AWD) system, typically with the V6 engines. Features Transmission Type Code: 42LE (for 3.0L V6), 41TE (for 3.3L V6 and some 2.4L applications) Fluid Specifications Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid +4), formerly ATF+3. Refer to manual for exact specification for model year. Fluid Capacity Transmission Fluid Capacity: Approx. 6.0 - 7.0 quarts (5.7 - 6.6 L) for a fluid service. 📐 Dimensions Exterior Length: Approx. 189.4 inches (4811 mm) Width: Approx. 72.1 inches (1831 mm) Height: Approx. 67.6 inches (1717 mm) Wheelbase Wheelbase: Approx. 112.1 inches (2847 mm) Weights Curb Weight Range: Approx. 3,700 - 4,100 lbs (1678 - 1860 kg), varies by engine and drivetrain. 🛡️ Safety Features Ratings NHTSA Front Impact: Likely 4-star for driver and front passenger (based on typical ratings for this era/segment). IIHS Side Impact: Ratings vary by year, check specific vehicle year for detailed IIHS data. Active Features ABS: Standard on most models, Antilock Braking System. Passive Features Airbags: Driver and front passenger airbags standard. Seat Belts: Front and rear seat belts with pretensioners for front occupants. 💡 Technology Features Infotainment Audio Options: AM/FM cassette/CD player, optional premium sound systems, rear seat entertainment options on some higher trims. Climate Control: Manual HVAC controls, optional automatic climate control systems. Driver Assistance Cruise Control: Standard on most trims. Connectivity Power Accessories: Power windows, power door locks, power sliding doors (optional on some models). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specifics). Transmission Fluid Change: Recommended every 30,000 to 60,000 miles (48,000 to 96,000 km), or as per severe driving conditions. Timing Belt Replacement: Critical for the 2.4L engine (interference engine). Typically every 60,000 to 100,000 miles (96,000 to 160,000 km). V6 engines often use timing chains. Fluid Specifications Engine Oil Type: API Certified SAE 5W-30 or 10W-30 (depending on ambient temperature). Refer to owner's manual for...
Ford Windstar, Toyota Sienna, Honda Odyssey, Chevrolet Venture/Silhouette/Trans Sport.
Key Features
Vehicle Highlights:
Spacious interior, flexible seating configurations, comfortable ride, availability of all-wheel drive on some models.
Manual Value Proposition
Benefit To Owner:
Empowers owners and independent repair shops with the technical knowledge to perform maintenance, diagnostics, and repairs efficiently and correctly, saving time and money.
📋 Manual Details
Coverage Areas
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Comprehensive engine diagnostics, overhaul procedures, timing belt replacement, cooling system, lubrication system, fuel delivery, emissions control systems.
Transmission Mechanical:
Automatic transmission (e.g., 42LE, 41TE) overhaul, repair, fluid service, torque converter replacement, electronic control unit (ECU) diagnostics.
Brakes:
Hydraulic system, brake fluid service, ABS diagnostics and repair, caliper and rotor replacement, parking brake adjustment.
Suspension Steering:
Front and rear suspension components, struts, shocks, control arms, ball joints, power steering system, steering rack, alignment procedures.
Electrical Electronics:
Wiring diagrams, charging system (alternator, battery), starting system, ignition system, lighting, power windows, power locks, interior electronics, fuse and relay identification, diagnostic trouble codes (DTCs).
Body Chassis:
Body panel repair, door mechanisms, interior trim removal, glass replacement, underbody components, chassis lubrication.
HVAC:
Air conditioning system service, refrigerant handling, heater core replacement, blower motor, climate control system diagnostics.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC interpretation.
Repair Overhaul:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Special Tools:
Identification and usage instructions for specialized tools required for specific repairs.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission rebuilds; includes detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Print Quality
Quality:
High-resolution scans, searchable text, clear diagrams and illustrations.
3.3L SOHC V6 (180 hp @ 5,200 rpm, 210 lb-ft @ 3,600 rpm) - Introduced later in the generation
Performance
Horsepower Range:
150-180 hp
Torque Range:
175-210 lb-ft
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Engine Codes
Common Engine Codes:
EDZ (2.4L I4), EAT (3.0L V6), EHB (3.3L V6)
Cooling System
Coolant Capacity:
Approx. 9.5 quarts (9.0 L)
🔧 Transmission
Standard
Transmission Standard:
4-Speed Automatic
Optional
Transmission Optional:
All-Wheel Drive (AWD) system, typically with the V6 engines.
Features
Transmission Type Code:
42LE (for 3.0L V6), 41TE (for 3.3L V6 and some 2.4L applications)
Fluid Specifications
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid +4), formerly ATF+3. Refer to manual for exact specification for model year.
Fluid Capacity
Transmission Fluid Capacity:
Approx. 6.0 - 7.0 quarts (5.7 - 6.6 L) for a fluid service.
📐 Dimensions
Exterior
Length:
Approx. 189.4 inches (4811 mm)
Width:
Approx. 72.1 inches (1831 mm)
Height:
Approx. 67.6 inches (1717 mm)
Wheelbase
Wheelbase:
Approx. 112.1 inches (2847 mm)
Weights
Curb Weight Range:
Approx. 3,700 - 4,100 lbs (1678 - 1860 kg), varies by engine and drivetrain.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Likely 4-star for driver and front passenger (based on typical ratings for this era/segment).
IIHS Side Impact:
Ratings vary by year, check specific vehicle year for detailed IIHS data.
Active Features
ABS:
Standard on most models, Antilock Braking System.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seat Belts:
Front and rear seat belts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio Options:
AM/FM cassette/CD player, optional premium sound systems, rear seat entertainment options on some higher trims.
Climate Control:
Manual HVAC controls, optional automatic climate control systems.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Power Accessories:
Power windows, power door locks, power sliding doors (optional on some models).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specifics).
Transmission Fluid Change:
Recommended every 30,000 to 60,000 miles (48,000 to 96,000 km), or as per severe driving conditions.
Timing Belt Replacement:
Critical for the 2.4L engine (interference engine). Typically every 60,000 to 100,000 miles (96,000 to 160,000 km). V6 engines often use timing chains.
Fluid Specifications
Engine Oil Type:
API Certified SAE 5W-30 or 10W-30 (depending on ambient temperature). Refer to owner's manual for exact viscosity and specification.
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a green or orange color. Mopar 5/100 coolant or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Problems 1:
Transmission solenoid issues (especially in the 42LE), A/C evaporator leaks, rear suspension sag, power window motor failures, potential head gasket issues on some V6 engines.
Common Problems 2:
EGR valve clogging (especially on 3.0L V6), O2 sensor failures, exhaust system corrosion, occasional electrical gremlins (e.g., power door locks).
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. The Voyager is the Chrysler-branded version.
Model Evolution
Generation Description:
This period covers the second generation (NS/GS) of the Chrysler Voyager, characterized by updated styling, improved safety features, and more powerful engine options compared to the first generation.
Production
Manufacturing Plants:
St. Louis Assembly (Missouri, USA) and Windsor Assembly (Ontario, Canada).
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Chrysler minivans, including variants of the Voyager/Grand Voyager, were frequently recognized on Car and Driver's '10Best' lists in the early to mid-1990s.
Ratings
Consumer Reports:
Ratings varied across model years, with some years showing better reliability than others, particularly concerning transmission and powertrain components. This manual provides the means to address common issues.