Chrysler Voyager Workshop Service Repair Manual 1996-1999
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🏷️ Basic Information Identification Make: Chrysler / Plymouth Model: Voyager / Grand Voyager / Caravan / Grand Caravan / Town & Country Generation: Second Generation (RS Body Style) Model Years Covered By Manual: 1996-1999 Specific Model Year Highlighted In Product Data: 1997 Codes Chassis Code: RS 👋 Introduction Market Position Segment: Minivan Target Audience: Families, fleet operators Competitive Analysis Key Competitors: Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Honda Odyssey, Toyota Sienna Key Features Versatility: Spacious interior, flexible seating arrangements Powertrain Options: Range of V6 engines known for durability and torque Manual Value Proposition: Provides essential information for owners and technicians to maintain, diagnose, and repair these popular vehicles, extending their lifespan and optimizing performance. 📋 Manual Details Coverage Areas Trim Levels Covered: SE, LE, ES, LX, LXI Body Styles Covered: Short Wheelbase (Voyager/Caravan) and Long Wheelbase (Grand Voyager/Grand Caravan) Page Count Total Pages: 1938 Manual Type Type: Workshop Service Repair Manual (Factory) Language Language: English Format Digital Format: PDF Delivery Method: Digital Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals, fuel injection, ignition, cooling, lubrication, emission controls, exhaust systems Transmission Systems: Manual transaxle (A598), automatic transaxle (details implied by coverage of engine and drive train), clutch Brake Systems: Hydraulic brake systems, ABS (Anti-lock Braking System), parking brake Suspension And Steering: Front and rear suspension components, steering gear, power steering Electrical Systems: Battery, starting system, charging system, lighting, instrument panel, vehicle speed control, wiper/washer, theft/security, chime warning, wiring diagrams Body And Frame: Frame, bumpers, body panels, doors, interior trim, HVAC system Procedures Included Maintenance: Scheduled maintenance, lubrication, fluid changes, filter replacements Repair And Rebuild: Detailed procedures for engine overhaul, transmission repair, brake component replacement, suspension work, electrical diagnostics and repair, bodywork Diagnostics: Troubleshooting guides, diagnostic procedures for all major systems Installation: Procedures for component replacement and alignment Technical Depth Depth Of Information: Comprehensive factory-level detail, suitable for professional technicians and advanced DIY mechanics Diagnostic Charts: Includes detailed diagnostic flowcharts and symptom-to-cause tables Specifications And Tolerances: Precise torque specifications, clearances, fluid capacities, and performance data 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (implied by factory PDF) Zoom Capability: Yes Print Quality Quality Rating: Excellent Factory Quality Readability: High clarity for diagrams and text Binding Type Binding: N/A (Digital) Paper Type Paper Type: N/A (Digital) File Size Size: 55.8 MB ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.4 L (148 cu in) Engine 1 Cylinders: 4 Engine 1 Valvetrain: DOHC (Double Overhead Camshaft), 16-Valve Engine 1 Fuel System: MPI (Multi-Point Fuel Injection) Engine 2 Displacement: 3.0 L (181 cu in) Engine 2 Cylinders: 6 Engine 2 Fuel System: MPI (Multi-Point Fuel Injection) Engine 3 Displacement: 3.3 L (201 cu in) Engine 3 Cylinders: 6 Engine 3 Fuel System: MPI (Multi-Point Fuel Injection) Engine 4 Displacement: 3.8 L (230 cu in) Engine 4 Cylinders: 6 Engine 4 Fuel System: MPI (Multi-Point Fuel Injection) Performance Horsepower Range: Approximately 150 hp (2.4L) to 180 hp (3.8L) Torque Range: Approximately 170 lb-ft (2.4L) to 240 lb-ft (3.8L) Fuel System Fuel Type: Unleaded gasoline (Diesel option mentioned for a different engine, not covered by main spec) Notes Diesel Option Mention: Manual indicates coverage for 2.5L Diesel and 2.0L Gas engines in one tab, suggesting potential for broader coverage than just the listed MPI engines, but focus is on the primary MPI offerings. 🔧 Transmission Standard Transmission Type: Automatic Transaxle (most common for this era, specific model not detailed in product info) Optional Manual Transmission Option: A598 Manual Transaxle (covered in Group 21) Features Overdrive: Likely equipped with overdrive gears for fuel efficiency 📐 Dimensions Exterior Wheelbase Short: Approx. 111.8 inches (Voyager/Caravan) Wheelbase Long: Approx. 119.2 inches (Grand Voyager/Grand Caravan/Town & Country) Weights Curb Weight Range: Approx. 3,700 - 4,300 lbs depending on configuration and engine 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 4-star driver, 4-star passenger (for 1997 models) Active Features ABS: Available Anti-lock Braking System (ABS) Passive Features Airbags: Driver and front passenger airbags Seatbelts: Front and rear seatbelts, with driver and passenger pretensioners 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette player, optional CD player available on some trims. Driver Assistance Cruise Control: Standard on most trims, controlled via steering wheel or stalk. ABS Integration: Anti-lock Braking System provides enhanced braking control. Connectivity Remote Keyless Entry: Available on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (detailed in manual). Transmission Fluid Interval: Refer to manual for specific intervals, often around 30,000-60,000 miles for filter and fluid service. Spark Plug Replacement: Varies by engine, typically 30,000-100,000 miles (depending on plug type, e.g., platinum/iridium). Fluid Specifications Engine Oil Type: SAE 5W-30 or 10W-30 recommended (specific viscosity depends on ambient temperature, consult manual). Coolant Type: Mopar Antifreeze/Coolant (ethylene glycol-based, typically orange or green...
Voyager / Grand Voyager / Caravan / Grand Caravan / Town & Country
Generation:
Second Generation (RS Body Style)
Model Years Covered By Manual:
1996-1999
Specific Model Year Highlighted In Product Data:
1997
Codes
Chassis Code:
RS
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Families, fleet operators
Competitive Analysis
Key Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Honda Odyssey, Toyota Sienna
Key Features
Versatility:
Spacious interior, flexible seating arrangements
Powertrain Options:
Range of V6 engines known for durability and torque
Manual Value Proposition:
Provides essential information for owners and technicians to maintain, diagnose, and repair these popular vehicles, extending their lifespan and optimizing performance.
📋 Manual Details
Coverage Areas
Trim Levels Covered:
SE, LE, ES, LX, LXI
Body Styles Covered:
Short Wheelbase (Voyager/Caravan) and Long Wheelbase (Grand Voyager/Grand Caravan)
Detailed procedures for engine overhaul, transmission repair, brake component replacement, suspension work, electrical diagnostics and repair, bodywork
Diagnostics:
Troubleshooting guides, diagnostic procedures for all major systems
Installation:
Procedures for component replacement and alignment
Technical Depth
Depth Of Information:
Comprehensive factory-level detail, suitable for professional technicians and advanced DIY mechanics
Diagnostic Charts:
Includes detailed diagnostic flowcharts and symptom-to-cause tables
Specifications And Tolerances:
Precise torque specifications, clearances, fluid capacities, and performance data
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (implied by factory PDF)
Zoom Capability:
Yes
Print Quality
Quality Rating:
Excellent Factory Quality
Readability:
High clarity for diagrams and text
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
File Size
Size:
55.8 MB
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.4 L (148 cu in)
Engine 1 Cylinders:
4
Engine 1 Valvetrain:
DOHC (Double Overhead Camshaft), 16-Valve
Engine 1 Fuel System:
MPI (Multi-Point Fuel Injection)
Engine 2 Displacement:
3.0 L (181 cu in)
Engine 2 Cylinders:
6
Engine 2 Fuel System:
MPI (Multi-Point Fuel Injection)
Engine 3 Displacement:
3.3 L (201 cu in)
Engine 3 Cylinders:
6
Engine 3 Fuel System:
MPI (Multi-Point Fuel Injection)
Engine 4 Displacement:
3.8 L (230 cu in)
Engine 4 Cylinders:
6
Engine 4 Fuel System:
MPI (Multi-Point Fuel Injection)
Performance
Horsepower Range:
Approximately 150 hp (2.4L) to 180 hp (3.8L)
Torque Range:
Approximately 170 lb-ft (2.4L) to 240 lb-ft (3.8L)
Fuel System
Fuel Type:
Unleaded gasoline (Diesel option mentioned for a different engine, not covered by main spec)
Notes
Diesel Option Mention:
Manual indicates coverage for 2.5L Diesel and 2.0L Gas engines in one tab, suggesting potential for broader coverage than just the listed MPI engines, but focus is on the primary MPI offerings.
🔧 Transmission
Standard
Transmission Type:
Automatic Transaxle (most common for this era, specific model not detailed in product info)
Optional
Manual Transmission Option:
A598 Manual Transaxle (covered in Group 21)
Features
Overdrive:
Likely equipped with overdrive gears for fuel efficiency
Approx. 3,700 - 4,300 lbs depending on configuration and engine
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4-star driver, 4-star passenger (for 1997 models)
Active Features
ABS:
Available Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Front and rear seatbelts, with driver and passenger pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette player, optional CD player available on some trims.
Driver Assistance
Cruise Control:
Standard on most trims, controlled via steering wheel or stalk.
ABS Integration:
Anti-lock Braking System provides enhanced braking control.
Connectivity
Remote Keyless Entry:
Available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (detailed in manual).
Transmission Fluid Interval:
Refer to manual for specific intervals, often around 30,000-60,000 miles for filter and fluid service.
Spark Plug Replacement:
Varies by engine, typically 30,000-100,000 miles (depending on plug type, e.g., platinum/iridium).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 10W-30 recommended (specific viscosity depends on ambient temperature, consult manual).
Coolant Type:
Mopar Antifreeze/Coolant (ethylene glycol-based, typically orange or green for this era, consult manual for exact type and mixture ratio).
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent DEXRON-III/MERCON for earlier models, manual will specify).
Known Issues
Common Wear Items:
CV joints, ball joints, tie rod ends, wheel bearings, ignition coils (especially on V6 engines), transmission solenoids, power steering pumps.
Engine Specific Concerns:
Head gaskets on 3.3L/3.8L engines can be a concern; oil leaks from valve covers and oil pans.
Transmission Concerns:
Some transmission internal wear or failure at higher mileage, often related to fluid maintenance.
📚 Vehicle History
Brand Heritage
Minivan Pioneer:
Chrysler is credited with inventing and popularizing the minivan segment in North America with the original Dodge Caravan and Plymouth Voyager.
Model Evolution
Generation Name:
Second Generation (RS Body Style)
Updates During Generation:
Introduced in 1996, this generation featured a significant redesign with a more aerodynamic shape, improved interior packaging, and optional all-wheel drive (though not explicitly detailed in this product's engine list). Minor updates occurred through 1999.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Chrysler minivans (including Voyager/Caravan variants) were frequent recipients of Car and Driver's 10Best awards in the early to mid-1990s, cementing their status as segment leaders.