The Chrysler Voyager, produced from 1996 through 2003, is a full-size minivan known for its spacious interior, versatile seating configurations, and comfortable ride, making it a popular choice for families. Built on the NS/GS platform, this vehicle offers a strong towing capacity for its class and was engineered with pioneering front-wheel-drive technology. Available with a 3.3L V6 or a more powerful 3.8L V6 engine, and paired with a 4-speed automatic transmission, the Voyager provides reliable performance for daily commuting and longer journeys. Its design prioritizes practicality and passenger comfort, solidifying its place among competitors like the Ford Windstar and Honda Odyssey. This comprehensive service and repair manual provides detailed information for all aspects of Voyager maintenance and repair for the 1996-2003 model years. It covers essential procedures such as oil changes, filter replacements, coolant flushes, and brake services, along with in-depth guides for engine mechanicals, fuel and ignition systems, transmissions, drivetrains, suspension, steering, braking, and electrical systems. Detailed troubleshooting guides, diagnostic procedures, and extensive wiring diagrams are included to assist owners and technicians in identifying and resolving issues efficiently. The manual's scope extends to body and interior repairs, HVAC systems, and specific technical specifications, ensuring a thorough understanding for effective vehicle upkeep. 🏷️ Basic Information Identification Make: Chrysler Model: Voyager Production Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Codes Platform: NS/GS (Long wheelbase variant of the Dodge Caravan/Plymouth Voyager) 👋 Introduction Market Position Segment: Full-size Minivan Competitive Analysis Competitors: Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna Key Features Features: Spacious interior, versatile seating configurations, comfortable ride, strong towing capacity for its class. Manual Value Proposition Value: Empowers DIY mechanics with detailed, accurate information to maintain and repair their Chrysler Voyager effectively, saving on labor costs. 📋 Manual Details Coverage Areas Coverage: All Service and Repair Page Count Estimated Page Count: 2000+ Manual Type Type: Comprehensive Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission control systems Transmission Systems: Automatic transmission (e.g., A604, 41TE) repair, service, diagnostics, fluid and filter replacement Drivetrain Systems: Front-wheel drive, axle shafts, differential, CV joints Suspension And Steering: Front and rear suspension components, steering system diagnosis and repair, power steering system Braking Systems: Front and rear brakes (disc/drum), ABS system diagnosis and repair, brake fluid service Electrical Systems: Wiring diagrams, charging system, starting system, lighting, instrument panel, body electrical components, power windows, locks, mirrors HVAC Systems: Heating, ventilation, and air conditioning system diagnosis, repair, refrigerant handling Body And Interior: Body panel repair, door mechanisms, interior trim, seating systems, glass replacement Diagnostics: On-board diagnostics (OBD-II) interpretation, fault code retrieval and diagnosis, troubleshooting guides Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, coolant flushes, brake inspections, tire rotations Repair Procedures: Engine component replacement (e.g., alternator, starter, water pump), transmission service, brake caliper replacement, suspension arm replacement Troubleshooting Guides: Step-by-step diagnostics for common drivability issues, electrical faults, and mechanical problems Wiring Diagrams: Detailed electrical schematics for all vehicle systems Technical Depth Depth: Comprehensive: Covers basic maintenance, routine service, advanced diagnostics, and complete component overhaul/rebuilds. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, printable pages Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 3.3L V6 (3301cc) Engine 1 Code: EGA Engine 1 Performance Hp: Approx. 158 hp @ 4700 rpm Engine 1 Performance Torque: Approx. 190 lb-ft @ 3300 rpm Optional Engine Engine 2: 3.8L V6 (3778cc) Engine 2 Code: L32 Engine 2 Performance Hp: Approx. 180 hp @ 4700 rpm Engine 2 Performance Torque: Approx. 235 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Engine Management ECM: Chrysler NGC (Next Generation Controller) or similar Emission Control Emission Systems: Catalytic converter, EGR valve, O2 sensors, EVAP system 🔧 Transmission Standard Transmission Type 1: 4-Speed Automatic Code 1: A604 / 41TE (Ultradrive) Optional Transmission Type 2: N/A (Only automatic was prevalent for these years) Features Transmission Features: Electronically controlled, Torque converter lock-up, Selectable low gear Fluid Specifications Transmission Fluid: ATF+4 (or equivalent ATF that meets Chrysler MS-9602 specifications) Fluid Capacity Capacity Liters: Approx. 4.5-5.5 liters (pan drop) 📐 Dimensions Exterior Wheelbase Mm: 3032 (119.4 inches) Length Mm: 4747 (186.9 inches) Width Mm: 1788 (70.4 inches) Height Mm: 1750 (68.9 inches) Weights Curb Weight Kg: Approx. 1800-1950 kg (depending on configuration) Cargo Cargo Volume Liters: Approx. 1470 - 4000+ liters (with rear seats removed/folded) Towing Towing Capacity Kg: Approx. 1633 kg (3600 lbs) with optional towing package 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: 4 Stars (for models with driver-side airbag) NHTSA Frontal Passenger Rating: 4 Stars (for models with passenger-side airbag) Active Features ABS: Standard on most models, optional on...