This Service Repair Workshop Manual provides comprehensive information for the Chrysler Voyager, covering production years from 1996 through 2005. The Voyager, a full-size minivan known for its practicality, spaciousness, and family-oriented design, offers flexible seating configurations and sliding rear doors, making it a versatile choice for transport. Throughout its NS/GS generation, Chrysler's commitment to accessible pricing and a strong market presence positioned the Voyager as a key competitor against rivals like the Honda Odyssey and Toyota Sienna. Available with a range of engine options, from a 2.4L inline-4 to various V6 configurations up to 3.8L, and typically equipped with a 4-speed automatic transaxle, the Voyager was engineered for everyday family use. This manual serves as an essential resource for owners, mechanics, and technicians, detailing every aspect of the Chrysler Voyager's maintenance and repair. It covers all major systems, including engine mechanicals, transmission and drivetrain, brakes, steering and suspension, and the electrical system, providing in-depth guidance for diagnostics, troubleshooting, and repair procedures. Within its extensive pages, you will find information on scheduled maintenance, fluid specifications, common known issues, and technical data crucial for keeping the vehicle in optimal condition. The manual's detailed explanations, step-by-step instructions, and high-resolution diagrams are designed to facilitate efficient and accurate servicing. 🏷️ Basic Information Identification Make: Chrysler Model: Voyager Generation: NS/GS (Third Generation) Production Years Covered By Manual: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Chassis Code: NS (early), GS (facelift) 👋 Introduction Market Position Vehicle Type: Minivan Segment: Full-size Minivan Competitive Analysis Key Competitors 1996-2005: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Lumina APV/Silhouette, Mercury Villager. Key Features Design Philosophy: Practicality, spaciousness, family-oriented transport. Distinctive Attributes: Sliding rear doors, flexible seating configurations, Stow 'n Go (later generations), accessible pricing. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Page Count Estimated Page Count: 1500+ 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, assembly, disassembly, timing, lubrication, cooling, fuel delivery (carburetor/injection), ignition, exhaust, emissions control. Transmission And Drivetrain: Automatic Transmission (A604, 41TE, 42LE), manual transmission (if applicable), transaxle, differential, CV joints, driveshafts. Brakes: Hydraulic system, ABS, front and rear disc/drum brake components, parking brake, hydraulic fluid specifications. Steering And Suspension: Power steering system, steering column, rack and pinion, suspension components (struts, shocks, control arms, ball joints, bushings), wheel alignment specifications. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, body control module (BCM). HVAC: Heating, ventilation, air conditioning (A/C) system operation, refrigerant R134a, components (compressor, condenser, evaporator), climate control systems. Body And Chassis: Body construction, panels, doors, glass, interior trim, exterior trim, bumpers, frame, rust prevention, sound deadening. Interior: Seats, seat belts, airbags, dashboard, center console, trim panels, door panels, carpeting, headliner. Procedures Included Scheduled Maintenance: Oil change intervals, filter replacements, fluid checks and changes, tire rotation, brake inspection, tune-up procedures. Troubleshooting: Diagnostic procedures for common problems, fault codes, symptom-based diagnosis for engine, transmission, electrical, and HVAC systems. Repair Procedures: Step-by-step instructions for component removal, installation, rebuilding, and replacement across all major vehicle systems. Diagnostics: Detailed diagnostic flowcharts, using scan tools, testing electrical circuits, pressure testing, and mechanical component testing. Technical Depth Depth Of Coverage: Comprehensive, covering everything from routine maintenance and inspections to complete engine and transmission rebuilds and complex electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Printability: Printable pages for on-the-job use. Print Quality Image Resolution: High-resolution images, diagrams, and schematics. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Option 1: 2.4L Inline-4 (4G64, Mitsubishi Eclipse engine) Engine Option 2: 3.0L V6 (3.0L 6G72 SOHC, Mitsubishi engine) Engine Option 3: 3.3L V6 (3.3L EGE SOHC, Chrysler) Engine Option 4: 3.8L V6 (3.8L EGH SOHC, Chrysler) Performance Horsepower Range: Approx. 130 hp (2.4L) to 180 hp (3.8L) Torque Range: Approx. 155 lb-ft (2.4L) to 235 lb-ft (3.8L) Fuel System Fuel Injection Type: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Required Octane: 87 (Octane Rating) 🔧 Transmission Standard Standard Transmission Type: 4-speed Automatic Transaxle (e.g., 41TE, 42LE) Optional Optional Transmission Type: 5-speed Manual Transaxle (rare, primarily on 2.4L models) Features Transmission Control: Electronic automatic transmission control, TorqueFlite (Chrysler branding for automatic). 📐 Dimensions Exterior Length: Approx. 189-195 inches (depending on year/trim) Width: Approx. 72 inches Height: Approx. 68-69 inches Interior Seating Capacity: 7-8 Passengers Cargo Cargo Volume Behind First Row: Approx. 100-150 cu. ft. (with seats removed/folded) Weights Curb Weight: Approx. 3800-4300 lbs 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: Likely 4-star driver, 5-star passenger (varies by year/test protocol) IIHS Small Overlap Front Crash Rating: Not applicable to models tested by IIHS during this period. Active Features Active Safety Features Available: Anti-lock Braking System (ABS) - standard on most...