Chrysler Voyager 1996-2001 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Generation: GS (Second Generation) Production Years: 1996-2001 Codes Chassis Code: GS 👋 Introduction Market Position Target Audience: Mechanical technicians and knowledgeable vehicle owners. Competitive Analysis Value Proposition: Enables owners to perform maintenance and repairs themselves, saving costs and gaining knowledge. Key Features Reliability: Provides the most reliable information available for servicing the vehicle. Completeness: Contains all necessary instructions for any repair the vehicle may require. Dealer Equivalency: Includes specifications and procedures comparable to authorized dealer service departments. Emphasis Symbols: Uses WARNING, CAUTION, and NOTE to highlight critical information. 📋 Manual Details Coverage Areas Covered Years: 1996, 1997, 1998, 1999, 2000, 2001 Vehicle Type: Minivan Page Count Estimated Page Count: Not Specified, but comprehensive Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage including removal, installation, and internal component overhaul. Transmission: Detailed repair and overhaul procedures for automatic transmissions. Fuel System: Covers fuel pump, injectors, lines, and emissions controls. Ignition System: Diagnostic and repair procedures for ignition coils, spark plugs, and timing. Lubrication System: Oil pump, filter, and lubrication circuit maintenance. Exhaust System: Components, diagnostics, and repair of exhaust manifolds, pipes, and mufflers. Electrical System: Wiring diagrams, component testing, charging system, starting system, lighting, and accessories. Body: Exterior and interior body repair, panel replacement, glass, and trim. Brakes: Inspection, repair, and maintenance of hydraulic system, ABS, rotors, pads, and calipers. Suspension Steering: Covers struts, shocks, control arms, ball joints, tie rods, and power steering. Heating Air Conditioning: Component identification, diagnosis, and service of HVAC system. Wheels Tires: Specifications, mounting, and rotation. Procedures Included Maintenance: Routine service, fluid changes, filter replacements, and inspections. Troubleshooting: Diagnostic charts and procedures for identifying and resolving common issues. Repair: Step-by-step instructions for component replacement and repair. Overhaul: Detailed procedures for engine and transmission rebuilds. Diagnostics: Emphasis on special aspects of product repair and component functions. Tune Ups: Procedures for optimizing engine performance. Removal Installation: Instructions for removing and installing major components. Assemblies Disassemblies: Detailed breakdown and reassembly of vehicle systems. Technical Depth Depth: Comprehensive, suitable for professional technicians and knowledgeable DIYers. Special Tools: Identifies and illustrates Chrysler special tool numbers where required. Proprietary Components: Includes instructions from respective component manufacturers for proprietary parts. Safety Emphasis: Highlights safety precautions, including the use of torque wrenches. 📊 Manual Specifications File Format Format: PDF Delivery Method: Electronic Delivery via Email Delivery Speed: Fast and Free Print Quality Printability: Yes, printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Searchability Text Search: Likely searchable text within the PDF (standard for professional manuals). ⚙️ Engine Specifications Primary Engine Engine Options: Likely includes 2.4L I4 (DOHC, 16-valve, 'EDZ') and 3.0L V6 (SOHC, 12-valve, '6G72') and 3.3L V6 (SOHC, 12-valve, 'EGA'). Specifics depend on model year. Engine Codes: EDZ (2.4L), 6G72 (3.0L V6), EGA (3.3L V6). Specific year application varies. Performance Horsepower Range: Approximately 150 hp (2.4L) to 180 hp (3.3L V6). Exact figures vary by engine and year. Torque Range: Approximately 160 lb-ft (2.4L) to 200 lb-ft (3.3L V6). Exact figures vary by engine and year. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI). Fuel Type: Unleaded Gasoline. Engine Management ECM: Engine Control Module (ECM) type and location described. 🔧 Transmission Standard Transmission Type Standard: Likely a 3-speed or 4-speed automatic transmission (e.g., A604/41TE or A670/42LE). Optional Transmission Type Optional: Depending on year and engine, a different automatic variant might be available. Features Shift Control: Electronic shift control covered. Fluid Specifications Transmission Fluid: Specifications for ATF+4 or equivalent fluids will be detailed. 📐 Dimensions Exterior Wheelbase: Approximately 112.2 inches (2850 mm). Length: Approximately 178.4 inches (4531 mm) to 181.7 inches (4615 mm) depending on configuration. Cargo Cargo Volume: Significant cargo capacity, configurable with folding/removable seats. Weights Curb Weight: Typically ranges from 3,500 to 4,000 lbs, depending on engine and equipment. 🛡️ Safety Features Ratings NHTSA Front Impact: Varied by year, generally 4-star for driver and passenger. IIHS Side Impact: Varied by year, 'Acceptable' to 'Good'. Active Features ABS: Anti-lock Braking System availability and function covered. Passive Features Airbags: Driver and front passenger airbags; potential for side airbags in later models. Seatbelts: Seatbelt system description and maintenance. 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with cassette and/or CD player. Optional premium audio systems. Navigation: Limited or no factory navigation systems typically available for this generation. Driver Assistance Cruise Control: Standard feature on most models. Connectivity Power Accessories: Power windows, power door locks, and power mirrors were common options. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000 to 7,500 miles depending on oil type and driving conditions (manual will specify). Transmission Fluid Change: Recommended every 30,000 to 60,000 miles (manual will provide specific intervals). Fluid Specifications Engine Oil: Typically SAE 5W-30 or 10W-30 depending on...
Exterior and interior body repair, panel replacement, glass, and trim.
Brakes:
Inspection, repair, and maintenance of hydraulic system, ABS, rotors, pads, and calipers.
Suspension Steering:
Covers struts, shocks, control arms, ball joints, tie rods, and power steering.
Heating Air Conditioning:
Component identification, diagnosis, and service of HVAC system.
Wheels Tires:
Specifications, mounting, and rotation.
Procedures Included
Maintenance:
Routine service, fluid changes, filter replacements, and inspections.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common issues.
Repair:
Step-by-step instructions for component replacement and repair.
Overhaul:
Detailed procedures for engine and transmission rebuilds.
Diagnostics:
Emphasis on special aspects of product repair and component functions.
Tune Ups:
Procedures for optimizing engine performance.
Removal Installation:
Instructions for removing and installing major components.
Assemblies Disassemblies:
Detailed breakdown and reassembly of vehicle systems.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and knowledgeable DIYers.
Special Tools:
Identifies and illustrates Chrysler special tool numbers where required.
Proprietary Components:
Includes instructions from respective component manufacturers for proprietary parts.
Safety Emphasis:
Highlights safety precautions, including the use of torque wrenches.
📊 Manual Specifications
File Format
Format:
PDF
Delivery Method:
Electronic Delivery via Email
Delivery Speed:
Fast and Free
Print Quality
Printability:
Yes, printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
Searchability
Text Search:
Likely searchable text within the PDF (standard for professional manuals).
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely includes 2.4L I4 (DOHC, 16-valve, 'EDZ') and 3.0L V6 (SOHC, 12-valve, '6G72') and 3.3L V6 (SOHC, 12-valve, 'EGA'). Specifics depend on model year.
Engine Codes:
EDZ (2.4L), 6G72 (3.0L V6), EGA (3.3L V6). Specific year application varies.
Performance
Horsepower Range:
Approximately 150 hp (2.4L) to 180 hp (3.3L V6). Exact figures vary by engine and year.
Torque Range:
Approximately 160 lb-ft (2.4L) to 200 lb-ft (3.3L V6). Exact figures vary by engine and year.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded Gasoline.
Engine Management
ECM:
Engine Control Module (ECM) type and location described.
🔧 Transmission
Standard
Transmission Type Standard:
Likely a 3-speed or 4-speed automatic transmission (e.g., A604/41TE or A670/42LE).
Optional
Transmission Type Optional:
Depending on year and engine, a different automatic variant might be available.
Features
Shift Control:
Electronic shift control covered.
Fluid Specifications
Transmission Fluid:
Specifications for ATF+4 or equivalent fluids will be detailed.
📐 Dimensions
Exterior
Wheelbase:
Approximately 112.2 inches (2850 mm).
Length:
Approximately 178.4 inches (4531 mm) to 181.7 inches (4615 mm) depending on configuration.
Cargo
Cargo Volume:
Significant cargo capacity, configurable with folding/removable seats.
Weights
Curb Weight:
Typically ranges from 3,500 to 4,000 lbs, depending on engine and equipment.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Varied by year, generally 4-star for driver and passenger.
IIHS Side Impact:
Varied by year, 'Acceptable' to 'Good'.
Active Features
ABS:
Anti-lock Braking System availability and function covered.
Passive Features
Airbags:
Driver and front passenger airbags; potential for side airbags in later models.
Seatbelts:
Seatbelt system description and maintenance.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with cassette and/or CD player. Optional premium audio systems.
Navigation:
Limited or no factory navigation systems typically available for this generation.
Driver Assistance
Cruise Control:
Standard feature on most models.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were common options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 to 7,500 miles depending on oil type and driving conditions (manual will specify).
Transmission Fluid Change:
Recommended every 30,000 to 60,000 miles (manual will provide specific intervals).
Fluid Specifications
Engine Oil:
Typically SAE 5W-30 or 10W-30 depending on ambient temperature (manual will confirm).
Coolant:
Chrysler's HOAT (Hybrid Organic Acid Technology) coolant or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Transmission Problems:
Certain automatic transmission models (especially early versions of the 41TE) were prone to solenoid issues and fluid leaks.
Cooling System:
Overheating due to radiator or water pump failures can occur. Intake manifold gasket leaks are also common on V6 engines.
Electrical Gremlins:
Common for this era of vehicle, including issues with power windows, door locks, and instrument clusters.
Spark Plugs
Spark Plug Type:
Typically platinum or iridium tipped spark plugs, with specific part numbers provided in the manual.
📚 Vehicle History
Brand Heritage
Chrysler Minivan:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager.
Model Evolution
Gs Generation:
The second generation (GS) saw significant updates in styling, safety, and powertrain compared to the first generation.
Production
Manufacturing Location:
Primarily St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Voyager and its siblings (Caravan, Town & Country) were frequently named to Car and Driver's Ten Best lists in their initial years, though specific mentions for the 1996-2001 generation may vary.
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