PLYMOUTH VOYAGER 1984-1990 Service Repair Manual

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🏷️ Basic Information Identification Make: Plymouth Model: Voyager Model Years Covered: 1984, 1985, 1986, 1987, 1988, 1989, 1990 Product Name: PLYMOUTH VOYAGER 1984-1990 Service Repair Manual Generation Generation: First Generation (AS) 👋 Introduction Market Position Market Position: The Plymouth Voyager was a groundbreaking minivan that redefined family transportation in the 1980s, pioneering the front-wheel-drive, car-based minivan segment. This manual serves the crucial need of maintaining and repairing this iconic vehicle, a task often undertaken by owners and independent workshops. Segment Creation: The Plymouth Voyager, along with the Dodge Caravan, is credited with creating the modern minivan segment, offering a practical, car-based alternative to traditional station wagons and vans. This manual is essential for maintaining the integrity of this pioneering design. Practical Innovation: The Voyager's success was driven by its innovative design that maximized interior space and flexibility with its front-wheel-drive, 'cab-forward' design, setting a new standard for family vehicles. Competitive Analysis Competitive Analysis: In its initial years, the Voyager faced little direct competition in the nascent minivan market, establishing itself as a leader. Later models competed with vehicles like the Ford Aerostar and Chevrolet Astro, though the Voyager's car-like handling and packaging offered a distinct advantage. This manual provides the necessary technical data to keep these vehicles performing optimally against their contemporary competitors and modern vehicles. Segment Dominance: The Voyager was so successful that it effectively created and dominated the minivan market for years, setting benchmarks for practicality, interior volume, and driving ease that competitors would strive to match. Key Features Key Features: The manual's extensive coverage, detailed illustrations, and factory-level technical data are its key features. The ability to zoom and print specific pages enhances usability for repair tasks. Its compatibility with both PC and Mac systems and the availability of alternative download links address common user needs. Utility For Owners: Empowers owners to perform routine maintenance and complex repairs themselves, saving money and extending the life of their vehicle. The digital format offers convenience and easy navigation. Mechanical Focus: This manual is heavily focused on mechanical and electrical repair, providing the in-depth knowledge required for hands-on servicing, a key differentiator from an owner's manual. Comprehensive Coverage: The sheer volume of information (over 5000 pages) signifies a truly comprehensive resource, covering virtually every aspect of vehicle maintenance and repair. 📋 Manual Details Coverage Areas Coverage Areas: Engine Overhaul and Rebuilding, Brakes, Sunroof, Timing Belt Replacement, Trouble Codes, Wiring Diagrams, Troubleshooting and Diagnostics, Engine Performance, Front End Procedures and Specifications, Suspension, Transmission Information, Air Conditioning Service and Capacities, Computer Diagnostic Codes, Firing Orders, Detailed Specifications, Factory Maintenance Schedules and Charts, Serpentine Belt Routings with Diagrams, Timing Belt Service Procedures, Driving Concerns, Complete Torque Specifications, U-Joint and CV-Joint Service Procedures, Repair Procedures, Complete Wiring Diagrams, Hundreds of Illustrations Page Count Page Count: Over 5000 Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Engine Performance and Control, Fuel System, Cooling System, Lubrication System, Exhaust System, Ignition System, Starting and Charging System, Brakes (Hydraulic and ABS if applicable), Steering System, Suspension System (Front and Rear), Drivetrain (Front Wheel Drive, CV Joints), Automatic and Manual Transmissions, Climate Control (HVAC), Electrical System (Wiring Diagrams, Components), Body and Frame, Interior and Exterior Trim, Safety Systems, Lighting, Instruments and Gauges Electrical Systems: Comprehensive coverage of the entire electrical system, including detailed wiring diagrams for all major components, fuses, relays, lighting, ignition, starting, charging, and accessory circuits. Troubleshooting guides for common electrical faults are included. Chassis And Body: Covers front and rear suspension components, steering linkage, subframe mounting, body panel alignment, door hardware, liftgate operation, interior trim removal and installation, and basic body repair techniques. Includes diagrams for all major body components. Fuel System Service: Detailed service procedures for fuel pumps, fuel lines, fuel filters, fuel injectors (EFI systems), and carburetors. Includes fuel pressure testing and diagnostic procedures for fuel delivery issues. Cooling And Heating: Detailed coverage of the engine cooling system (radiator, water pump, thermostat, hoses, fan) and the HVAC (heating, ventilation, and air conditioning) system, including diagnosis and repair of refrigerant leaks, blower motor issues, and climate control module faults. Engine Performance Control: Detailed coverage of engine sensors (e.g., MAP, TPS, coolant temp), actuators, and the engine control unit (ECU) or carburetor adjustments for optimal performance and emissions. Emission Control: Information on emission control systems, including catalytic converters, EGR valves, and PCV systems, along with diagnostic procedures for emission-related faults. Procedures Included Procedures Included: Engine tune-up, engine overhaul and rebuilding, timing belt replacement, serpentine belt routing and replacement, brake system diagnosis and repair, suspension component replacement, steering system service, transmission service and overhaul, air conditioning system service and recharge, diagnostic code retrieval and interpretation, electrical component testing and replacement, body panel repair, sunroof operation and repair, troubleshooting of drivability issues,...

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Type: Car

Vendor:

Sku: 278514

Collections: ALL Plymouth

Availability: In stock

Tags: 1984 1985 1986 1987 1988 1989 1990 Car Cars Plymouth VOYAGER

Product variants

Description

🏷️ Basic Information

Identification

Make:

Plymouth

Model:

Voyager

Model Years Covered:

1984, 1985, 1986, 1987, 1988, 1989, 1990

Product Name:

PLYMOUTH VOYAGER 1984-1990 Service Repair Manual

Generation

Generation:

First Generation (AS)

👋 Introduction

Market Position

Market Position:

The Plymouth Voyager was a groundbreaking minivan that redefined family transportation in the 1980s, pioneering the front-wheel-drive, car-based minivan segment. This manual serves the crucial need of maintaining and repairing this iconic vehicle, a task often undertaken by owners and independent workshops.

Segment Creation:

The Plymouth Voyager, along with the Dodge Caravan, is credited with creating the modern minivan segment, offering a practical, car-based alternative to traditional station wagons and vans. This manual is essential for maintaining the integrity of this pioneering design.

Practical Innovation:

The Voyager's success was driven by its innovative design that maximized interior space and flexibility with its front-wheel-drive, 'cab-forward' design, setting a new standard for family vehicles.

Competitive Analysis

Competitive Analysis:

In its initial years, the Voyager faced little direct competition in the nascent minivan market, establishing itself as a leader. Later models competed with vehicles like the Ford Aerostar and Chevrolet Astro, though the Voyager's car-like handling and packaging offered a distinct advantage. This manual provides the necessary technical data to keep these vehicles performing optimally against their contemporary competitors and modern vehicles.

Segment Dominance:

The Voyager was so successful that it effectively created and dominated the minivan market for years, setting benchmarks for practicality, interior volume, and driving ease that competitors would strive to match.

Key Features

Key Features:

The manual's extensive coverage, detailed illustrations, and factory-level technical data are its key features. The ability to zoom and print specific pages enhances usability for repair tasks. Its compatibility with both PC and Mac systems and the availability of alternative download links address common user needs.

Utility For Owners:

Empowers owners to perform routine maintenance and complex repairs themselves, saving money and extending the life of their vehicle. The digital format offers convenience and easy navigation.

Mechanical Focus:

This manual is heavily focused on mechanical and electrical repair, providing the in-depth knowledge required for hands-on servicing, a key differentiator from an owner's manual.

Comprehensive Coverage:

The sheer volume of information (over 5000 pages) signifies a truly comprehensive resource, covering virtually every aspect of vehicle maintenance and repair.

📋 Manual Details

Coverage Areas

Coverage Areas:

Engine Overhaul and Rebuilding, Brakes, Sunroof, Timing Belt Replacement, Trouble Codes, Wiring Diagrams, Troubleshooting and Diagnostics, Engine Performance, Front End Procedures and Specifications, Suspension, Transmission Information, Air Conditioning Service and Capacities, Computer Diagnostic Codes, Firing Orders, Detailed Specifications, Factory Maintenance Schedules and Charts, Serpentine Belt Routings with Diagrams, Timing Belt Service Procedures, Driving Concerns, Complete Torque Specifications, U-Joint and CV-Joint Service Procedures, Repair Procedures, Complete Wiring Diagrams, Hundreds of Illustrations

Page Count

Page Count:

Over 5000

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine Mechanical, Engine Performance and Control, Fuel System, Cooling System, Lubrication System, Exhaust System, Ignition System, Starting and Charging System, Brakes (Hydraulic and ABS if applicable), Steering System, Suspension System (Front and Rear), Drivetrain (Front Wheel Drive, CV Joints), Automatic and Manual Transmissions, Climate Control (HVAC), Electrical System (Wiring Diagrams, Components), Body and Frame, Interior and Exterior Trim, Safety Systems, Lighting, Instruments and Gauges

Electrical Systems:

Comprehensive coverage of the entire electrical system, including detailed wiring diagrams for all major components, fuses, relays, lighting, ignition, starting, charging, and accessory circuits. Troubleshooting guides for common electrical faults are included.

Chassis And Body:

Covers front and rear suspension components, steering linkage, subframe mounting, body panel alignment, door hardware, liftgate operation, interior trim removal and installation, and basic body repair techniques. Includes diagrams for all major body components.

Fuel System Service:

Detailed service procedures for fuel pumps, fuel lines, fuel filters, fuel injectors (EFI systems), and carburetors. Includes fuel pressure testing and diagnostic procedures for fuel delivery issues.

Cooling And Heating:

Detailed coverage of the engine cooling system (radiator, water pump, thermostat, hoses, fan) and the HVAC (heating, ventilation, and air conditioning) system, including diagnosis and repair of refrigerant leaks, blower motor issues, and climate control module faults.

Engine Performance Control:

Detailed coverage of engine sensors (e.g., MAP, TPS, coolant temp), actuators, and the engine control unit (ECU) or carburetor adjustments for optimal performance and emissions.

Emission Control:

Information on emission control systems, including catalytic converters, EGR valves, and PCV systems, along with diagnostic procedures for emission-related faults.

Procedures Included

Procedures Included:

Engine tune-up, engine overhaul and rebuilding, timing belt replacement, serpentine belt routing and replacement, brake system diagnosis and repair, suspension component replacement, steering system service, transmission service and overhaul, air conditioning system service and recharge, diagnostic code retrieval and interpretation, electrical component testing and replacement, body panel repair, sunroof operation and repair, troubleshooting of drivability issues, routine maintenance procedures, lubrication and fluid changes, exhaust system repair, ignition system troubleshooting and repair

Brake Procedures:

Front and rear brake pad replacement, caliper service and replacement, rotor resurfacing or replacement, brake bleeding procedures, parking brake adjustment and repair, ABS system diagnosis and repair (if equipped).

Engine Performance Tuning:

Details for adjusting idle speed, ignition timing (if applicable), fuel mixture adjustments (for carbureted models), and troubleshooting of engine performance issues like misfires, rough idling, and poor acceleration. Includes information on emission control systems.

Suspension Alignment Specs:

Includes front and rear wheel alignment specifications (caster, camber, toe) required for proper handling and tire wear. Manual will specify adjustment procedures.

Engine Mount Replacement:

Procedures for inspecting and replacing engine and transmission mounts to reduce vibration and noise transfer into the cabin.

Drivetrain Service:

Includes procedures for front axle removal, CV joint boot replacement, and propeller shaft service (for AWD variants if applicable, though typically FWD). U-joint service is also covered.

Engine Timing Adjustment:

Detailed procedures for setting and verifying ignition timing (if applicable) and engine timing belt alignment.

Technical Depth

Technical Depth:

Comprehensive, from basic maintenance to in-depth engine and transmission rebuilding. Includes detailed diagnostic procedures, troubleshooting guides, and factory specifications. Suitable for professional mechanics and advanced DIYers.

Engine Rebuild Depth:

Full engine overhaul instructions, including cylinder head removal and reconditioning, piston and connecting rod installation, crankshaft and bearing service, camshaft and valvetrain adjustment, timing gear/chain/belt procedures, oil pump service, and torque specifications for all critical fasteners.

Wiring Diagram Detail:

Extremely detailed, color-coded (if original publication was color) or clearly labeled wiring diagrams illustrating the complete electrical system, including power distribution, grounds, and component connections, facilitating accurate troubleshooting and repair.

Diagnostic Trouble Codes:

Provides a comprehensive list of diagnostic trouble codes (DTCs) for engine management systems, transmission control, and other electronically controlled modules, along with step-by-step diagnostic procedures to pinpoint fault causes.

Torque Specifications:

Extensive lists of torque specifications for all critical fasteners across engine, transmission, suspension, brakes, and chassis components, crucial for ensuring proper assembly and preventing component failure.

Troubleshooting Guides:

Extensive, systematic troubleshooting guides for common drivability symptoms, electrical faults, and mechanical issues, often presented in a flowchart or step-by-step format.

Diagnostic Tools Usage:

May reference the use of specific diagnostic tools or multimeters for electrical testing and sensor readings, guiding the user through proper diagnostic methodologies.

📊 Manual Specifications

File Format

File Format:

File Access:

Downloaded as a zip file, requiring decompression software like WinZip or a built-in OS utility (Archive Utility for Mac, Stuffit Expander recommended).

Compatibility:

Works on all computers, PC & MAC. PDF format is universally compatible with standard document viewers.

Searchability:

PDF documents are typically searchable, allowing users to quickly find specific information by typing in relevant keywords (e.g., 'timing belt', 'brake pad').

Print Quality

Print Quality:

High resolution, allowing for detailed zooming and printing of specific pages without loss of clarity.

Illustrations Detail:

Hundreds of illustrations, diagrams, and charts are included, providing visual guidance for complex procedures and component identification. Zoom capability ensures clarity of intricate details.

Diagram Clarity:

Technical diagrams are typically clear and well-labeled, aiding in the understanding of complex assemblies and routing of components.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Format

Digital Advantages:

The PDF format allows for quick searching of keywords and phrases, enabling faster access to specific repair information compared to traditional printed manuals.

⚙️ Engine Specifications

Primary Engine

Primary Engine Options:

2.2L (135 cu in) Turbocharged I4, 2.5L (153 cu in) I4 (Naturally Aspirated and Turbocharged), 2.6L (158 cu in) Mitsubishi I4

Engine Displacement Common:

2.2L, 2.5L, 2.6L

Engine Variants Covered:

Includes details for naturally aspirated and turbocharged versions of the 2.2L and 2.5L engines, as well as the Mitsubishi 2.6L engine.

Performance

Engine Performance Notes:

Horsepower and torque varied significantly based on engine choice and whether it was naturally aspirated or turbocharged. The manual will detail specific output for each variant.

Horsepower Range:

Varies by engine, approximately 96 hp (2.6L) to 140 hp (2.2L Turbo).

Fuel System

Fuel System Types:

Carbureted (early models) and Fuel Injection (Electronic Fuel Injection - EFI, later models and turbocharged variants).

Turbocharger Systems:

Detailed information on the operation, maintenance, and repair of the factory turbocharger systems, including wastegate operation, intercooler service, and turbocharger unit replacement.

Fuel Pump Diagnosis:

Procedures for testing fuel pump output pressure and flow, as well as troubleshooting electrical issues related to the fuel pump circuit.

🔧 Transmission

Standard

Standard Transmission:

Manual Transaxle (e.g., 4-speed, 5-speed)

Manual Transmission Service:

Covers clutch inspection, adjustment, and replacement, as well as internal transmission repairs and gear selection diagnostics for manual transaxles.

Optional

Optional Transmission:

Automatic Transaxle (e.g., 3-speed TorqueFlite A904, 4-speed A670)

Automatic Transmission Types:

Details on the Chrysler TorqueFlite series automatic transmissions, including their operation, maintenance, and common repair procedures.

Features

Transmission Features:

Front-wheel drive layout. Manuals will cover clutch operation, gear linkage adjustment, transmission fluid type and capacity, and internal component service procedures.

Transmission Diagnostic Codes:

Manual covers diagnostic trouble codes (DTCs) relevant to automatic transmission control modules (if applicable) and provides troubleshooting steps for common transmission performance issues.

Cv Joint Service:

Detailed procedures for servicing Constant Velocity (CV) joints and drive axles, including inspection, boot replacement, and axle shaft removal/installation.

Gear Ratio Information:

The manual will typically include detailed gear ratio information for both manual and automatic transmissions, which is useful for performance modifications or troubleshooting.

📐 Dimensions

Exterior

Wheelbase:

Approximately 112.1 inches (standard wheelbase)

Length:

Approximately 175-176 inches (standard wheelbase)

Width:

Approximately 71.5 inches

Height:

Approximately 68.5 inches

Weights

Curb Weight:

Varies by configuration, typically between 2,900 - 3,500 lbs.

Gross Vehicle Weight Rating:

GVWR varies by configuration, typically in the range of 4,300-4,900 lbs. Manual will provide specific ratings.

Interior

Seating Capacity:

Typically 5 to 7 passengers, depending on configuration (2-2-3 or 2-3-2 seating).

Interior Volume:

The compact exterior dimensions belied a surprisingly spacious and versatile interior, a key design feature documented within the manual's context.

Cargo

Cargo Volume:

Significant cargo capacity with rear seats removed, offering substantial utility for hauling goods or equipment. Specific volumes will be detailed in OEM specifications.

🛡️ Safety Features

Ratings

Safety Ratings Notes:

As the vehicle predates widespread standardized crash testing by agencies like NHTSA and IIHS, specific ratings are not readily available. However, the manual will cover safety-related systems such as brake components, steering, and potential chassis integrity issues.

Active Features

Active Features:

Power-assisted brakes, power steering (on most models), rear-wheel anti-lock brakes (RWAL) introduced later in the generation.

Power Steering Service:

Covers diagnosis and repair of the power steering system, including pump, hoses, and steering gear/rack.

Passive Features

Passive Features:

Seat belts (lap and shoulder belts), reinforced passenger compartment, child safety seat anchors (LATCH system not present in this era).

Child Safety:

While lacking modern LATCH systems, the manual will cover seat belt anchor points and recommendations for child restraint system installation within the vehicle's design constraints.

Seat Belt Systems:

Details on seat belt operation, maintenance, and replacement, including pre-tensioners if applicable to later models in the range.

💡 Technology Features

Infotainment

Infotainment Systems:

Basic AM/FM radio, optional cassette player, analog gauges, and basic climate controls. Manual will cover diagnostic and repair for these systems.

Gauge Cluster Diagnostics:

Covers troubleshooting for instrument panel issues, including speedometer, tachometer (if equipped), fuel gauge, temperature gauge, and warning lights.

Radio And Speaker Service:

Covers removal, installation, and troubleshooting of the factory radio, speakers, and antenna system.

Interior Lighting:

Covers diagnosis and replacement of interior dome lights, map lights, and other cabin illumination components.

Driver Assistance

Driver Assistance:

Limited. Power steering was common. ABS was an optional feature on later models. Cruise control was also an option. Manual will detail the operation and repair of these systems.

Cruise Control Service:

Manual will detail troubleshooting and repair of the cruise control system, including vacuum hoses (if applicable) and electronic control units.

ABS System Diagnosis:

If equipped with ABS, the manual provides diagnostic procedures for wheel speed sensors, ABS control module, and hydraulic modulator.

Connectivity

Connectivity:

None in the modern sense. Analog connections for audio accessories were the extent of 'connectivity'.

🔧 Maintenance

Service Intervals

Service Intervals General:

Oil changes: 3,000-5,000 miles or 3-6 months. Filter changes: concurrent with oil changes. Spark plugs: 30,000-60,000 miles depending on type. Timing belt: critical on 2.2L/2.5L Turbo and 2.5L naturally aspirated engines, typically 60,000-90,000 miles or 5-7 years. The manual provides specific intervals for each component and engine variant.

Timing Belt Importance:

The 2.2L and 2.5L engines use a timing belt that is an 'interference' design on many variants, meaning if it breaks, severe engine damage can occur. The manual stresses the critical nature of timely replacement.

Fluid Change Intervals:

Provides specific intervals for changing power steering fluid, brake fluid, and coolant based on mileage and time, ensuring optimal performance and longevity of these systems.

Spark Plug Service:

Provides guidance on selecting the correct spark plugs for each engine variant and the recommended replacement intervals based on plug type (conventional, platinum).

Air Filter Replacement:

Recommended intervals for replacing the engine air filter to ensure proper engine breathing and performance.

Fluid Specifications

Engine Oil Spec:

API SG or SF, SAE 5W-30 or 10W-30 (check specific engine and climate conditions). Manual will list exact API classification and viscosity grades.

Coolant Spec:

Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Mopar Antifreeze/Coolant (MS-7170) or equivalent. Manual specifies capacity and type.

Transmission Fluid Spec:

Automatic Transmission Fluid: ATF+3 or ATF+4 (later transmissions might specify this, early ones typically Dexron II or equivalent). Manual transmission fluid: SAE 75W-90 or 80W-90 GL-4. Manual will detail exact specifications and capacities.

Brake Fluid Spec:

DOT 3 brake fluid. Manual will detail capacity and bleeding procedures.

Power Steering Fluid Spec:

Mopar Power Steering Fluid or equivalent; consult manual for exact specification and capacity.

Manual Transmission Fluid Spec:

SAE 75W-90 or 80W-90 GL-4 gear oil for manual transaxles. Manual will specify capacity and change intervals.

Wheel Bearing Grease Spec:

If serviceable wheel bearings are present, the manual will specify the correct type of grease.

Known Issues

Common Issues:

Head gasket leaks (especially on turbocharged engines), turbocharger wear, carburetor issues, aging electrical components (alternator, starter, wiring harnesses), suspension wear (ball joints, bushings), exhaust system rust, radiator and cooling system leaks, automatic transmission problems (torque converter, valve body).

Climate Control Issues:

Common issues with A/C system refrigerant leaks, compressor failure, blend door actuators, and heater core leaks. Manual provides diagnosis and repair procedures.

Suspension Wear Points:

Frequent wear on ball joints, tie rod ends, control arm bushings, and strut mounts due to vehicle weight and typical use as a family vehicle. Manual provides wear limits and replacement procedures.

Electrical System Quirks:

Common issues with aging wiring harnesses, corroded connectors, and failing relays or switches, particularly in high-moisture areas. Manual provides detailed wiring diagrams and troubleshooting for these problems.

Engine Mounts:

Engine mounts can degrade over time, leading to excessive vibration. Manual covers inspection and replacement procedures.

Exhaust System Corrosion:

Susceptibility to rust and corrosion on the exhaust system components, especially in areas with road salt. Manual provides part identification for replacement.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Plymouth, a division of Chrysler, was known for producing affordable and practical vehicles. The Voyager was one of its most successful and influential models.

Chrysler Synergy:

Part of Chrysler Corporation's successful K-car lineage, benefiting from shared components and engineering expertise, contributing to its initial reliability and market acceptance.

Model Evolution

Model Evolution:

Launched for the 1984 model year as part of the 'K-car' platform derivatives, the Voyager, along with its Dodge Caravan sibling, revolutionized the automotive landscape. Key updates during this generation included engine improvements, introduction of turbocharging, and potential updates to transmissions and braking systems.

Platform Basis:

Based on Chrysler's innovative U.S. K-car platform, which allowed for a unibody construction and front-wheel drive that maximized interior space.

Facelift Notes:

While the core platform remained consistent, minor styling updates and feature enhancements occurred throughout the generation, which are detailed in the manual's context.

Market Impact:

The Voyager's introduction fundamentally altered the automotive market, shifting consumer preferences towards practical, family-oriented vehicles and inspiring numerous competitors.

Production

Production Location:

Windsor, Ontario, Canada (St. Louis, Missouri for some later models)

Introduction Year: