The Chrysler Voyager, a key player in the mid-size minivan segment, was produced from 1996 to 2003. This second-generation model, built on the NS/GS platform, offered a spacious interior, flexible seating configurations, and a comfortable ride, making it a popular choice for families. Available with a range of engines, including 2.4L inline-four and 3.0L or 3.3L V6 options, and an optional all-wheel-drive system, the Voyager provided versatility for various needs. Chrysler’s pioneering legacy in the minivan market is evident in the Voyager's design, which aimed to balance practicality with passenger comfort and convenience, competing with established models from Ford, Toyota, Honda, and Chevrolet. This comprehensive workshop service manual is designed to guide owners, technicians, and mechanics through the maintenance, diagnosis, and repair of the Chrysler Voyager models from 1996 through 2003. It covers all major systems, including detailed procedures for engine mechanicals, transmission overhauls, brake systems, suspension and steering, electrical and electronic components, body and chassis work, and HVAC systems. The manual provides step-by-step repair instructions, routine maintenance schedules, troubleshooting guides for common issues, and essential technical specifications, empowering users to maintain their vehicle's performance and reliability. 🏷️ Basic Information Identification Make: Chrysler Model: Voyager Codes Platform Code: NS/GS (Second Generation) 👋 Introduction Market Position Segment: Mid-size Minivan Competitive Analysis Competitors: Ford Windstar, Toyota Sienna, Honda Odyssey, Chevrolet Venture/Silhouette/Trans Sport. Key Features Vehicle Highlights: Spacious interior, flexible seating configurations, comfortable ride, availability of all-wheel drive on some models. Manual Value Proposition Benefit To Owner: Empowers owners and independent repair shops with the technical knowledge to perform maintenance, diagnostics, and repairs efficiently and correctly, saving time and money. 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Comprehensive engine diagnostics, overhaul procedures, timing belt replacement, cooling system, lubrication system, fuel delivery, emissions control systems. Transmission Mechanical: Automatic transmission (e.g., 42LE, 41TE) overhaul, repair, fluid service, torque converter replacement, electronic control unit (ECU) diagnostics. Brakes: Hydraulic system, brake fluid service, ABS diagnostics and repair, caliper and rotor replacement, parking brake adjustment. Suspension Steering: Front and rear suspension components, struts, shocks, control arms, ball joints, power steering system, steering rack, alignment procedures. Electrical Electronics: Wiring diagrams, charging system (alternator, battery), starting system, ignition system, lighting, power windows, power locks, interior electronics, fuse and relay identification, diagnostic trouble codes (DTCs). Body Chassis: Body panel repair, door mechanisms, interior trim removal, glass replacement, underbody components, chassis lubrication. HVAC: Air conditioning system service, refrigerant handling, heater core replacement, blower motor, climate control system diagnostics. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC interpretation. Repair Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Special Tools: Identification and usage instructions for specialized tools required for specific repairs. Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds; includes detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Quality: High-resolution scans, searchable text, clear diagrams and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 2.4L DOHC I4 (150 hp @ 5,200 rpm, 175 lb-ft @ 3,800 rpm) Engine 2: 3.0L SOHC V6 (150-158 hp @ 5,200-5,400 rpm, 180-190 lb-ft @ 3,600-4,000 rpm) Engine 3: 3.3L SOHC V6 (180 hp @ 5,200 rpm, 210 lb-ft @ 3,600 rpm) - Introduced later in the generation Performance Horsepower Range: 150-180 hp Torque Range: 175-210 lb-ft Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Codes Common Engine Codes: EDZ (2.4L I4), EAT (3.0L V6), EHB (3.3L V6) Cooling System Coolant Capacity: Approx. 9.5 quarts (9.0 L) 🔧 Transmission Standard Transmission Standard: 4-Speed Automatic Optional Transmission Optional: All-Wheel Drive (AWD) system, typically with the V6 engines. Features Transmission Type Code: 42LE (for 3.0L V6), 41TE (for 3.3L V6 and some 2.4L applications) Fluid Specifications Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid +4), formerly ATF+3. Refer to manual for exact specification for model year. Fluid Capacity Transmission Fluid Capacity: Approx. 6.0 - 7.0 quarts (5.7 - 6.6 L) for a fluid service. 📐 Dimensions Exterior Length: Approx. 189.4 inches (4811 mm) Width: Approx. 72.1 inches (1831 mm) Height: Approx. 67.6 inches (1717 mm) Wheelbase Wheelbase: Approx. 112.1 inches (2847 mm) Weights Curb Weight Range: Approx. 3,700 - 4,100 lbs (1678 - 1860 kg), varies by engine and drivetrain. 🛡️ Safety Features Ratings NHTSA Front Impact: Likely 4-star for driver and front passenger (based on typical ratings for this era/segment). IIHS Side Impact: Ratings vary by year, check specific vehicle...