Chrysler Voyager 2000 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 2000 Codes Platform: NS (North America) 👋 Introduction Market Position Vehicle Segment: Minivan Target Demographic: Families seeking versatile and practical transportation. Competitive Analysis Primary Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager. Key Features Van Configuration: Front-engine, front-wheel-drive configuration. Seating Capacity: Typically 7-8 passengers with multiple seating configurations. Sliding Door: Standard rear passenger sliding side door for easy access. 📋 Manual Details Coverage Areas Primary Coverage: 2000 Chrysler Voyager (North America) Secondary Coverage Notes: May also cover closely related models/platforms like Dodge Caravan and Plymouth Grand Voyager of the same generation with minor variations. Specific VIN ranges are often critical for precise applicability. Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital (Likely PDF or similar, printable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, rebuild procedures, cylinder head, block, pistons, crankshaft, camshaft, valve train, timing components (belts/chains), oil pump, oil pan, lubrication system. Engine Management: Fuel injection system (MPI), ignition system, emissions control systems (EGR, catalytic converter, evaporative emissions), sensors (crankshaft, camshaft, O2, MAP, ECT), actuators, ECU/PCM diagnostics and repair, OBD-II diagnostics. Transmission Automatic: Overhaul procedures for the 41TE (3-Speed Automatic Transaxle), including torque converter, planetary gear sets, clutches, bands, valve body, hydraulic system, electronic controls, fluid service. Chassis Suspension: Front suspension (struts, control arms, ball joints, sway bar), rear suspension (leaf springs, shocks), steering system (rack and pinion, power steering pump, fluid, column), alignment specifications. Brakes: Front disc brakes (calipers, rotors, pads), rear drum brakes (shoes, drums, wheel cylinders), parking brake system, hydraulic system (master cylinder, lines, booster), ABS system (sensors, modulator, warning lamp). Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting system (headlights, taillights, interior), wiring diagrams for all circuits, fuses, relays, body control module (BCM), power windows, locks, mirrors. HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant, charging), heating system (heater core, blower motor, controls), climate control panel diagnostics. Body Exterior: Body panel removal and installation (doors, hood, liftgate), glass replacement, trim components, exterior lighting, bumpers, body sealant and corrosion protection. Body Interior: Seat removal and installation, interior trim panels, dashboard assembly, instrument cluster, upholstery, sound deadening materials, seat belts, airbags (system diagnostics and precautions). Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid changes, tire rotation, wiper blade replacement, battery inspection. Diagnostics: Detailed troubleshooting charts for common symptoms, diagnostic trouble codes (DTCs) interpretation and resolution, component testing procedures (resistance, voltage, continuity). Component Replacement: Step-by-step instructions for replacing major components like alternators, starters, water pumps, fuel pumps, radiators, steering racks, brake calipers, wheel bearings. Rebuilding: Comprehensive instructions for overhauling engines and automatic transmissions, including specifications for all internal parts. Wiring Diagrams: Detailed, component-level wiring diagrams for all vehicle systems, including pinouts and wire colors. Technical Depth Depth: Comprehensive workshop level. Covers everything from basic fluid changes to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repairs. 📊 Manual Specifications File Format Digital Format: Likely PDF, optimized for digital viewing and printing. Searchable text is highly probable. Print Quality Print Quality Notes: Digital files allow for high-quality printing of diagrams and text, preserving clarity of technical illustrations and data. Binding Type Binding Type Notes: Not applicable for digital format; if printed version, typically spiral-bound or perfect-bound for durability in workshop use. Paper Type Paper Type Notes: Not applicable for digital format; if printed version, often on durable, glossy paper to withstand workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: 3.3L V6 (3295cc) Engine Code: EBD (Grand Cherokee/Voyager V6) Configuration: Overhead Valve (OHV), V6 Bore X Stroke: 94.5 mm x 79.5 mm Compression Ratio: 8.9:1 Horsepower: 180 hp @ 5000 RPM Torque: 205 lb-ft @ 3200 RPM Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Regular Gasoline (87 Octane recommended) Fluid Specifications Engine Oil Type: API Service SG or SH, SAE 5W-30 (or 10W-30 in warmer climates) Engine Oil Capacity: 4.5 US quarts (4.3 liters) with filter change Coolant Type: Chrysler OAT (5/10x30) Antifreeze/Coolant, Blue Coolant Capacity: 12.0 US quarts (11.4 liters) 🔧 Transmission Standard Transmission Type: 41TE Automatic Transaxle Number Of Gears: 3-Speed Automatic with Overdrive Features Transmission Control: Electronically controlled with lock-up torque converter. Fluid Specifications Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid Type 4) Transmission Fluid Capacity: 7.0 US quarts (6.6 liters) for initial fill (check dipstick for exact level) 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 190.3 inches (4833 mm) Width: 76.7 inches (1948 mm) Height: 68.4 inches (1737 mm) Weights Curb Weight: Approx. 4,000 - 4,300 lbs (1814 - 1950 kg), depending on configuration. Gross Vehicle Weight Rating Gvwr: Approx. 5,500 - 5,700 lbs (2495 - 2585 kg) Towing Capacity: Up to 3,500 lbs (1588...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Year:

Codes

Platform:

NS (North America)

👋 Introduction

Market Position

Vehicle Segment:

Minivan

Target Demographic:

Families seeking versatile and practical transportation.

Competitive Analysis

Primary Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Villager.

Key Features

Van Configuration:

Front-engine, front-wheel-drive configuration.

Seating Capacity:

Typically 7-8 passengers with multiple seating configurations.

Sliding Door:

Standard rear passenger sliding side door for easy access.

📋 Manual Details

Coverage Areas

Primary Coverage:

2000 Chrysler Voyager (North America)

Secondary Coverage Notes:

May also cover closely related models/platforms like Dodge Caravan and Plymouth Grand Voyager of the same generation with minor variations. Specific VIN ranges are often critical for precise applicability.

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (Likely PDF or similar, printable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, rebuild procedures, cylinder head, block, pistons, crankshaft, camshaft, valve train, timing components (belts/chains), oil pump, oil pan, lubrication system.

Engine Management:

Fuel injection system (MPI), ignition system, emissions control systems (EGR, catalytic converter, evaporative emissions), sensors (crankshaft, camshaft, O2, MAP, ECT), actuators, ECU/PCM diagnostics and repair, OBD-II diagnostics.

Transmission Automatic:

Overhaul procedures for the 41TE (3-Speed Automatic Transaxle), including torque converter, planetary gear sets, clutches, bands, valve body, hydraulic system, electronic controls, fluid service.

Chassis Suspension:

Front suspension (struts, control arms, ball joints, sway bar), rear suspension (leaf springs, shocks), steering system (rack and pinion, power steering pump, fluid, column), alignment specifications.

Brakes:

Front disc brakes (calipers, rotors, pads), rear drum brakes (shoes, drums, wheel cylinders), parking brake system, hydraulic system (master cylinder, lines, booster), ABS system (sensors, modulator, warning lamp).

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting system (headlights, taillights, interior), wiring diagrams for all circuits, fuses, relays, body control module (BCM), power windows, locks, mirrors.

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant, charging), heating system (heater core, blower motor, controls), climate control panel diagnostics.

Body Exterior:

Body panel removal and installation (doors, hood, liftgate), glass replacement, trim components, exterior lighting, bumpers, body sealant and corrosion protection.

Body Interior:

Seat removal and installation, interior trim panels, dashboard assembly, instrument cluster, upholstery, sound deadening materials, seat belts, airbags (system diagnostics and precautions).

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid changes, tire rotation, wiper blade replacement, battery inspection.

Diagnostics:

Detailed troubleshooting charts for common symptoms, diagnostic trouble codes (DTCs) interpretation and resolution, component testing procedures (resistance, voltage, continuity).

Component Replacement:

Step-by-step instructions for replacing major components like alternators, starters, water pumps, fuel pumps, radiators, steering racks, brake calipers, wheel bearings.

Rebuilding:

Comprehensive instructions for overhauling engines and automatic transmissions, including specifications for all internal parts.

Wiring Diagrams:

Detailed, component-level wiring diagrams for all vehicle systems, including pinouts and wire colors.

Technical Depth

Depth:

Comprehensive workshop level. Covers everything from basic fluid changes to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repairs.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF, optimized for digital viewing and printing. Searchable text is highly probable.

Print Quality

Print Quality Notes:

Digital files allow for high-quality printing of diagrams and text, preserving clarity of technical illustrations and data.

Binding Type

Binding Type Notes:

Not applicable for digital format; if printed version, typically spiral-bound or perfect-bound for durability in workshop use.

Paper Type

Paper Type Notes:

Not applicable for digital format; if printed version, often on durable, glossy paper to withstand workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

3.3L V6 (3295cc)

Engine Code:

EBD (Grand Cherokee/Voyager V6)

Configuration:

Overhead Valve (OHV), V6

Bore X Stroke:

94.5 mm x 79.5 mm

Compression Ratio:

8.9:1

Horsepower:

180 hp @ 5000 RPM

Torque:

205 lb-ft @ 3200 RPM

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Regular Gasoline (87 Octane recommended)

Fluid Specifications

Engine Oil Type:

API Service SG or SH, SAE 5W-30 (or 10W-30 in warmer climates)

Engine Oil Capacity:

4.5 US quarts (4.3 liters) with filter change

Coolant Type:

Chrysler OAT (5/10x30) Antifreeze/Coolant, Blue

Coolant Capacity:

12.0 US quarts (11.4 liters)

🔧 Transmission

Standard

Transmission Type:

41TE Automatic Transaxle

Number Of Gears:

3-Speed Automatic with Overdrive

Features

Transmission Control:

Electronically controlled with lock-up torque converter.

Fluid Specifications

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid Type 4)

Transmission Fluid Capacity:

7.0 US quarts (6.6 liters) for initial fill (check dipstick for exact level)

📐 Dimensions

Exterior

Wheelbase:

119.3 inches (3030 mm)

Length:

190.3 inches (4833 mm)

Width:

76.7 inches (1948 mm)

Height:

68.4 inches (1737 mm)

Weights

Curb Weight:

Approx. 4,000 - 4,300 lbs (1814 - 1950 kg), depending on configuration.

Gross Vehicle Weight Rating Gvwr:

Approx. 5,500 - 5,700 lbs (2495 - 2585 kg)

Towing Capacity:

Up to 3,500 lbs (1588 kg) with optional towing package.

Cargo

Cargo Volume Behind First Row:

Approx. 150.0 cu ft (4.25 m3)

Cargo Volume Behind Second Row:

Approx. 78.0 cu ft (2.21 m3)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Four Stars (2000 model year)

NHTSA Front Impact Passenger:

Four Stars (2000 model year)

NHTSA Side Impact Front Driver:

Five Stars (2000 model year)

NHTSA Side Impact Front Passenger:

Five Stars (2000 model year)

Active Features

Standard Anti-lock Braking System (ABS) on all models.

Traction Control:

Optional Traction Control System (TCS) available on some trims.

Passive Features

Airbags Front:

Driver and front passenger airbags.

Seatbelts:

Three-point seatbelts for all occupants, with front seat pretensioners.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system compatibility.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player and/or CD player, optional Infinity premium audio system.

Rear Entertainment:

Optional rear seat entertainment system with video cassette player (VCP) and rear screen.

Driver Assistance

Cruise Control:

Standard cruise control system.

Connectivity

Remote Keyless Entry:

Optional remote keyless entry system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first, using synthetic blend or full synthetic oil.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on operating conditions.

Spark Plug Replacement:

Every 100,000 miles (160,000 km) with original equipment (platinum tip) spark plugs.

Coolant Flush Replacement:

Every 5 years or 100,000 miles (160,000 km) with OAT coolant.

Transmission Fluid Change:

Every 60,000 miles (96,000 km) or 4 years, whichever comes first.

Known Issues

Common Issue Powertrain Vibration:

Engine and transmission mounts can degrade, leading to vibration, especially at idle or during acceleration. Torque converter clutch shudder can occur due to transmission fluid contamination or internal wear.

Common Issue Electrical:

Headlight switch failures, power window motor issues, and dashboard indicator light failures are reported. Chronically, power sliding door mechanisms can be problematic.

Common Issue HVAC:

Blend door actuator failures in the HVAC system can lead to poor temperature control and airflow direction issues.

Common Issue Suspension Steering:

Wear in ball joints, tie rod ends, and sway bar links can cause clunking noises and affect steering feel. Power steering pump leaks or noisy operation.

Fluid Specifications

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+4 or Mopar power steering fluid.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984, establishing a strong market presence and reputation for practicality and innovation in this vehicle type.

Model Evolution

Generation:

Third Generation (1996-2000) NS Platform.

Design Changes For 2000:

Minor cosmetic updates, potential feature shuffling between trim levels. Represents the final year of the NS platform before the introduction of the RS platform.

Production

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Inc.)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Chrysler minivans (including Voyager variants) were frequently recognized on Car and Driver's 10Best lists in previous generations, highlighting their innovation and market impact.