PLYMOUTH VOYAGER 1996-1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Plymouth Model: Voyager Model Years Covered: 1996, 1997, 1998, 1999 Codes Chassis Code: NS (Second Generation) 👋 Introduction Market Position Positioning: Targeted at DIY enthusiasts and independent repair shops seeking in-depth technical information to maintain and repair the 1996-1999 Plymouth Voyager. Competitive Analysis Alternatives: Comparable to factory service manuals or reputable aftermarket manuals (e.g., Chilton, Haynes), but offering the direct specifications and procedures from the original manufacturer. Key Features Features: Extensive coverage of all major vehicle systems, hundreds of illustrations and photos, DIY-friendly instructions, potential for significant cost savings on repairs. Value Proposition Cost Savings: Empowers owners to perform DIY repairs, saving money on labor costs and parts markups compared to dealership or independent mechanic prices. Target Audience User Base: Ideal for individuals who enjoy performing their own automotive maintenance and repairs, possess basic mechanical aptitude, and want access to professional-level information. 📋 Manual Details Coverage Areas General Coverage: Comprehensive factory service and repair information for all aspects of the 1996-1999 Plymouth Voyager. Page Count Estimated Page Count: Likely exceeds 1500 pages (typical for factory service manuals covering multiple years and configurations). Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Print (implied by description of illustrations and photos, though digital versions are common for this era). 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emissions control. Transmission Systems: Automatic transmission (likely A604/41TE/42LE variants), clutch, drivetrain components (axles, U-joints, differential). Braking Systems: Front and rear brakes (disc/drum configurations), ABS system, hydraulic lines, parking brake. Suspension Steering: Front and rear suspension, steering gear, power steering system, wheel alignment. Electrical Systems: Complete wiring diagrams, starting system, charging system, lighting system, accessories, body electronics, diagnostic connector (OBD-II). HVAC Systems: Air conditioning system (compressor, condenser, evaporator, refrigerant), heater system, blower motor, climate controls. Body Interior Exterior: Body panels, doors, windows, glass, wipers, seats, interior trim, exterior trim, bumpers, locks, latches. Powertrain Control: Engine control module (ECM) diagnostics, fuel injection strategy, idle speed control, and sensor operations. Chassis Systems: Wheels, tires, lug nut torque specifications, wheel bearing service, hub replacement. Body And Frame: Body panel replacement, rust repair, structural integrity, door hinge adjustment, tailgate service, convertible top (if applicable), and chassis component alignment. Body Electrical: Power windows, power door locks, power mirrors, interior lighting, exterior lighting, horn, radio system, and control modules. Procedures Included Maintenance Procedures: Routine maintenance checks, fluid changes, filter replacements, lubrication, tune-ups. Repair Procedures: Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Troubleshooting: Diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all major systems. Diagnostic Procedures: OBD-II diagnostic trouble codes (DTCs), sensor testing, actuator testing, troubleshooting charts for drivability and performance issues. Rebuild Procedures: Detailed instructions for rebuilding major components like engines, transmissions, and power steering pumps, including component specifications and tolerances. Component Replacement: Detailed procedures for replacing common wear items such as brake pads, rotors, ball joints, tie rod ends, wheel bearings, and engine/transmission mounts. Technical Depth Depth: Factory-level diagnostic and repair procedures, including detailed specifications, torque values, and special tool requirements. Electrical Diagnostics: Extensive wiring diagrams with component locations, connector pinouts, and voltage/resistance testing procedures for all electrical circuits. Special Tools: Identifies and explains the use of specific Chrysler/Mopar factory tools required for certain repairs or diagnostic procedures, ensuring accuracy and completeness. 📊 Manual Specifications File Format Format: Likely a compilation of original Chrysler service manuals, possibly including specific sections for different powertrain configurations and model year updates. If digital, expect a high-quality PDF with searchable text and embedded images. Print Quality Quality: Professionally printed with clear, legible text and high-resolution illustrations and photographs. Binding Type Binding: Durable binding (e.g., spiral-bound or perfect-bound) suitable for workshop use. Paper Type Paper Quality: Heavy-duty paper stock designed to withstand grease and frequent handling in a workshop environment. Format Searchability: If digital (PDF), expect searchable text for quick information retrieval. If print, rely on comprehensive index and table of contents. Organization: Typically organized into logical sections covering each major system, with sub-sections for specific components and procedures, making it easy to navigate. ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L DOHC I4 (150 hp @ 5200 rpm, 170 lb-ft @ 4400 rpm), 3.0L SOHC V6 (150 hp @ 5100 rpm, 167 lb-ft @ 3000 rpm), 3.3L OHV V6 (158 hp @ 4400 rpm, 195 lb-ft @ 3200 rpm), 3.8L OHV V6 (180 hp @ 4700 rpm, 230 lb-ft @ 3600 rpm). Performance Performance Considerations: V6 engines offered better power and torque for hauling and highway driving, while the 2.4L I4 provided better fuel economy. Manual covers performance tuning and diagnostics for all engines. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-port injection (MPI). Engine Code Examples Engine Codes: Common engine codes include ECH (2.4L...

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Sku: 276329

Collections: ALL Plymouth

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Tags: 1996 1997 1998 1999 Car Cars Plymouth VOYAGER

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Description

🏷️ Basic Information

Identification

Make:

Plymouth

Model:

Voyager

Model Years Covered:

1996, 1997, 1998, 1999

Codes

Chassis Code:

NS (Second Generation)

👋 Introduction

Market Position

Positioning:

Targeted at DIY enthusiasts and independent repair shops seeking in-depth technical information to maintain and repair the 1996-1999 Plymouth Voyager.

Competitive Analysis

Alternatives:

Comparable to factory service manuals or reputable aftermarket manuals (e.g., Chilton, Haynes), but offering the direct specifications and procedures from the original manufacturer.

Key Features

Features:

Extensive coverage of all major vehicle systems, hundreds of illustrations and photos, DIY-friendly instructions, potential for significant cost savings on repairs.

Value Proposition

Cost Savings:

Empowers owners to perform DIY repairs, saving money on labor costs and parts markups compared to dealership or independent mechanic prices.

Target Audience

User Base:

Ideal for individuals who enjoy performing their own automotive maintenance and repairs, possess basic mechanical aptitude, and want access to professional-level information.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive factory service and repair information for all aspects of the 1996-1999 Plymouth Voyager.

Page Count

Estimated Page Count:

Likely exceeds 1500 pages (typical for factory service manuals covering multiple years and configurations).

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Print (implied by description of illustrations and photos, though digital versions are common for this era).

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, emissions control.

Transmission Systems:

Automatic transmission (likely A604/41TE/42LE variants), clutch, drivetrain components (axles, U-joints, differential).

Braking Systems:

Front and rear brakes (disc/drum configurations), ABS system, hydraulic lines, parking brake.

Suspension Steering:

Front and rear suspension, steering gear, power steering system, wheel alignment.

Electrical Systems:

Complete wiring diagrams, starting system, charging system, lighting system, accessories, body electronics, diagnostic connector (OBD-II).

HVAC Systems:

Air conditioning system (compressor, condenser, evaporator, refrigerant), heater system, blower motor, climate controls.

Body Interior Exterior:

Body panels, doors, windows, glass, wipers, seats, interior trim, exterior trim, bumpers, locks, latches.

Powertrain Control:

Engine control module (ECM) diagnostics, fuel injection strategy, idle speed control, and sensor operations.

Chassis Systems:

Wheels, tires, lug nut torque specifications, wheel bearing service, hub replacement.

Body And Frame:

Body panel replacement, rust repair, structural integrity, door hinge adjustment, tailgate service, convertible top (if applicable), and chassis component alignment.

Body Electrical:

Power windows, power door locks, power mirrors, interior lighting, exterior lighting, horn, radio system, and control modules.

Procedures Included

Maintenance Procedures:

Routine maintenance checks, fluid changes, filter replacements, lubrication, tune-ups.

Repair Procedures:

Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Troubleshooting:

Diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all major systems.

Diagnostic Procedures:

OBD-II diagnostic trouble codes (DTCs), sensor testing, actuator testing, troubleshooting charts for drivability and performance issues.

Rebuild Procedures:

Detailed instructions for rebuilding major components like engines, transmissions, and power steering pumps, including component specifications and tolerances.

Component Replacement:

Detailed procedures for replacing common wear items such as brake pads, rotors, ball joints, tie rod ends, wheel bearings, and engine/transmission mounts.

Technical Depth

Depth:

Factory-level diagnostic and repair procedures, including detailed specifications, torque values, and special tool requirements.

Electrical Diagnostics:

Extensive wiring diagrams with component locations, connector pinouts, and voltage/resistance testing procedures for all electrical circuits.

Special Tools:

Identifies and explains the use of specific Chrysler/Mopar factory tools required for certain repairs or diagnostic procedures, ensuring accuracy and completeness.

📊 Manual Specifications

File Format

Format:

Likely a compilation of original Chrysler service manuals, possibly including specific sections for different powertrain configurations and model year updates. If digital, expect a high-quality PDF with searchable text and embedded images.

Print Quality

Quality:

Professionally printed with clear, legible text and high-resolution illustrations and photographs.

Binding Type

Binding:

Durable binding (e.g., spiral-bound or perfect-bound) suitable for workshop use.

Paper Type

Paper Quality:

Heavy-duty paper stock designed to withstand grease and frequent handling in a workshop environment.

Format

Searchability:

If digital (PDF), expect searchable text for quick information retrieval. If print, rely on comprehensive index and table of contents.

Organization:

Typically organized into logical sections covering each major system, with sub-sections for specific components and procedures, making it easy to navigate.

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.4L DOHC I4 (150 hp @ 5200 rpm, 170 lb-ft @ 4400 rpm), 3.0L SOHC V6 (150 hp @ 5100 rpm, 167 lb-ft @ 3000 rpm), 3.3L OHV V6 (158 hp @ 4400 rpm, 195 lb-ft @ 3200 rpm), 3.8L OHV V6 (180 hp @ 4700 rpm, 230 lb-ft @ 3600 rpm).

Performance

Performance Considerations:

V6 engines offered better power and torque for hauling and highway driving, while the 2.4L I4 provided better fuel economy. Manual covers performance tuning and diagnostics for all engines.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-port injection (MPI).

Engine Code Examples

Engine Codes:

Common engine codes include ECH (2.4L I4), EDB (3.0L V6), EDZ (3.3L V6), ERH (3.8L V6).

Engine Displacements

Displacements:

2.4 Liters (2424 cc), 3.0 Liters (2972 cc), 3.3 Liters (3301 cc), 3.8 Liters (3778 cc).

🔧 Transmission

Standard

Standard Transmission:

Automatic Transmission (e.g., Chrysler A604/41TE/42LE 4-speed automatic).

Optional

Optional Transmission:

Manual transmission was available in some markets and earlier generations, but less common or unavailable for these specific model years, particularly in North America. Manual likely focuses on automatic transmission service.

Features

Automatic Features:

Electronic control, torque converter lock-up.

Transmission Codes

Transmission Codes:

Common automatic transmission codes are 41TE, 42LE, 42AE. The manual will detail specifics for each.

📐 Dimensions

Exterior

Wheelbase:

112.1 inches (standard wheelbase)

Length:

Approximately 178-180 inches (standard wheelbase)

Weights

Curb Weight:

Varies by engine and configuration, typically ranging from 3,500 to 4,000 lbs.

Cargo

Cargo Volume:

Significant cargo capacity due to minivan design, with fold-flat rear seats for maximum space. Exact volume varies with configuration and seat removal.

🛡️ Safety Features

Ratings

NHTSA Ratings:

Varies by year and specific test, but generally good for its class. Frontal crash test results should be consulted from specific NHTSA archives.

Active Features

Active Safety:

Anti-lock Braking System (ABS) available on some models and as an option.

Passive Features

Passive Safety:

Driver and front passenger airbags, three-point seat belts for all seating positions, child seat anchor points (LATCH).

💡 Technology Features

Infotainment

Infotainment Options:

Basic AM/FM radio with cassette or CD player, optional premium sound systems, and rear-seat entertainment options on some higher trims.

Driver Assistance

Driver Assistance:

Limited by modern standards. Cruise control was standard or optional. ABS was available.

Connectivity

Connectivity Features:

Minimal connectivity features for the era. No Bluetooth or USB ports. Auxiliary input for audio devices may be present on some aftermarket head units.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 miles or 6 months for synthetic oil, or 3,000-5,000 miles for conventional oil (refer to manual for precise recommendations based on driving conditions).

Transmission Fluid Change:

Recommended every 30,000-60,000 miles, depending on transmission type and driving habits. Manual will specify exact interval and fluid type.

Spark Plug Replacement:

Varies by engine: 2.4L I4 typically 60,000-100,000 miles, V6 engines vary (e.g., 3.3L/3.8L V6 often 100,000 miles with platinum plugs).

Fluid Specifications

Engine Oil Specification:

Typically SAE 5W-30 or 10W-30, API certified. Manual will confirm viscosity and API service category.

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid) or equivalent for later transmissions, or ATF+3 for earlier versions. Manual will specify the exact Mopar P/N.

Coolant Specification:

Ethylene glycol-based coolant, typically a 50/50 mixture with distilled water. Mopar Antifreeze/Coolant, 5-Year/100,000-Mile Formula is common.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid, as specified by the manufacturer. Manual will specify.

Known Issues

Common Problems:

Transmission solenoid issues (especially in the A604/41TE), power steering pump leaks, window regulator failures, ignition coil failures, and occasional head gasket issues on V6 engines. Door lock actuator problems are also not uncommon.

Fluid Capacities

Engine Oil Capacity:

Varies by engine: 2.4L I4 typically around 4.5 quarts, V6 engines typically around 4.0-4.5 quarts. Manual will provide exact capacity.

Transmission Fluid Capacity:

Typically around 6-8 quarts for a pan drop and refill, higher for a full torque converter drain. Manual will specify.

Common Issues

Common Engine Issues:

Oil leaks from valve cover gaskets or oil pan, PCV valve issues, intake manifold gasket leaks (especially on older V6s), spark plug fouling, and ignition system component failures.

📚 Vehicle History

Brand Heritage

Plymouth History:

Plymouth was a marque of Chrysler Corporation, known for producing affordable and practical vehicles. The Voyager was a pioneering minivan.

Model Evolution

Voyager Evolution:

The 1996-1999 models represent the second generation of the Dodge Caravan/Plymouth Voyager/Chrysler Town & Country minivans, featuring a significant redesign with improved aerodynamics, safety, and powertrain options compared to the first generation.

Production

Manufacturing Location:

Typically produced in North America, with major assembly plants in Canada and the United States.

Model Significance

Minivan Pioneer:

The Voyager, along with its Dodge and Chrysler siblings, defined the modern minivan segment, offering unprecedented practicality and passenger comfort for families.