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Chrysler Voyager 1996-2003 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Generation: GS (Second Generation) Codes Platform: NS (shared with Plymouth Voyager, Dodge Caravan, Dodge Grand Caravan) 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families and individuals seeking practical, versatile transportation. The manual targets DIY mechanics, independent repair shops, and owners who prefer to perform their own maintenance and repairs. Competitive Analysis Competitors: Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Toyota Sienna, Honda Odyssey, Mercury Villager. Key Features Vehicle Strengths: Spacious interior, flexible seating configurations, comfortable ride, strong V6 engine options, available all-wheel drive (AWD). Manual Value Proposition: Provides in-depth technical knowledge essential for maintaining and repairing this generation of Chrysler Voyager, saving owners significant costs associated with dealership service. 📋 Manual Details Coverage Areas Regions Covered: Primarily North America (USDM, CAN), with potential applicability to European/Australian variants based on shared components. Page Count Estimated Pages: 1500+ Manual Type Type: Full Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system. Drivetrain: Transmission (automatic), clutch (if applicable to specific configurations), driveshafts, axles, differentials, AWD systems (if equipped). Chassis: Suspension (front and rear), steering system, brake system (hydraulic and mechanical components), wheel alignment. Electrical: Wiring diagrams, battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules, engine control modules (ECM/PCM). Body: Exterior body panels, interior trim, doors, windows, seats, HVAC system, body seals, glass replacement. Procedures Included Maintenance: Routine inspections, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, spark plug replacement, belt and hose inspection/replacement. Repair: Component removal and installation, rebuild procedures for major assemblies (engine, transmission), diagnostics and troubleshooting for all systems. Diagnostics: On-board diagnostics (OBD-II) troubleshooting, diagnostic trouble codes (DTCs), symptom-based diagnostics, component testing procedures. Technical Depth Depth: Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls. Includes detailed diagnostic flowcharts and specifications. 📊 Manual Specifications File Format Format Type: PDF Searchability: Likely text-searchable due to PDF format, enabling quick information retrieval. Print Quality Resolution: Variable, but typically optimized for clarity of text, diagrams, and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 3.0L V6 (Mitsubishi 6G72 SOHC) Engine 1 Power: Approx. 150 hp @ 5000 rpm Engine 1 Torque: Approx. 180 lb-ft @ 3000 rpm Engine 2: 3.3L V6 (Chrysler EBB OHV) Engine 2 Power: Approx. 158 hp @ 4500 rpm Engine 2 Torque: Approx. 195 lb-ft @ 3200 rpm Engine 3: 3.8L V6 (Chrysler EGG OHV) Engine 3 Power: Approx. 166 hp @ 4400 rpm Engine 3 Torque: Approx. 227 lb-ft @ 3200 rpm Fuel System Injection Type: Multi-port Fuel Injection (MPI) for all V6 engines. Fuel Type: Unleaded Gasoline (87 octane recommended) 🔧 Transmission Standard Transmission Type Standard: 4-speed Automatic Transaxle (Chrysler 41TE/42LE) Optional Transmission Type Optional: All-Wheel Drive (AWD) system integrated with the 4-speed automatic transaxle on select models. Features Transmission Fluid Spec: ATF+3 (Mopar) 📐 Dimensions Exterior Wheelbase: Approx. 112.3 inches (2852 mm) Length: Approx. 189.4 inches (4811 mm) Width: Approx. 74.0 inches (1880 mm) Height: Approx. 68.7 inches (1745 mm) Cargo Cargo Volume Behind 1St Row: Approx. 140.5 cu ft (4000 L) Cargo Volume Behind 2Nd Row: Approx. 83.5 cu ft (2364 L) Weights Curb Weight Min: Approx. 3700 lbs (1678 kg) Curb Weight Max: Approx. 4200 lbs (1905 kg) for AWD models 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (for certain model years/configurations) NHTSA Front Impact Passenger: 4 Stars (for certain model years/configurations) IIHS Side Impact: Acceptable (varies by year and equipment) Active Features ABS: Standard on most models, optional on some early trims. Traction Control: Optional on select models, particularly AWD variants. Passive Features Airbags: Driver and front passenger airbags standard. Optional side airbags became available on later models. Seat Belts: Three-point belts for all seating positions, with front pretensioners. 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette and CD player options. Premium Infinity sound systems were available on higher trims. Navigation: Factory-installed GPS navigation systems were optional on later models. Driver Assistance Cruise Control: Standard on most models. Connectivity Auxiliary Input: Not typically equipped with standard aux inputs; aftermarket solutions may be required. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 to 7,500 miles (5,000 to 12,000 km) depending on oil type and driving conditions. Consult manual for specific recommendations. Transmission Fluid Change Interval: Every 30,000 to 60,000 miles (50,000 to 100,000 km) for the automatic transmission. ATF+3 fluid is critical. Spark Plug Replacement Interval: Every 30,000 to 100,000 miles (50,000 to 160,000 km) depending on spark plug type (conventional, platinum, iridium). Fluid Specifications Engine Oil Viscosity: SAE 5W-30 is common for most V6 engines, consult manual for specific viscosity based on ambient temperature. Coolant Type:...
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Chrysler Voyager 1996-2003 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Generation:
GS (Second Generation)
Codes
Platform:
NS (shared with Plymouth Voyager, Dodge Caravan, Dodge Grand Caravan)
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families and individuals seeking practical, versatile transportation. The manual targets DIY mechanics, independent repair shops, and owners who prefer to perform their own maintenance and repairs.
Competitive Analysis
Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Toyota Sienna, Honda Odyssey, Mercury Villager.
Key Features
Vehicle Strengths:
Spacious interior, flexible seating configurations, comfortable ride, strong V6 engine options, available all-wheel drive (AWD).
Manual Value Proposition:
Provides in-depth technical knowledge essential for maintaining and repairing this generation of Chrysler Voyager, saving owners significant costs associated with dealership service.
📋 Manual Details
Coverage Areas
Regions Covered:
Primarily North America (USDM, CAN), with potential applicability to European/Australian variants based on shared components.
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system.
Drivetrain:
Transmission (automatic), clutch (if applicable to specific configurations), driveshafts, axles, differentials, AWD systems (if equipped).
Chassis:
Suspension (front and rear), steering system, brake system (hydraulic and mechanical components), wheel alignment.
Electrical:
Wiring diagrams, battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules, engine control modules (ECM/PCM).
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, body seals, glass replacement.
Procedures Included
Maintenance:
Routine inspections, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, spark plug replacement, belt and hose inspection/replacement.
Repair:
Component removal and installation, rebuild procedures for major assemblies (engine, transmission), diagnostics and troubleshooting for all systems.
Diagnostics:
On-board diagnostics (OBD-II) troubleshooting, diagnostic trouble codes (DTCs), symptom-based diagnostics, component testing procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls. Includes detailed diagnostic flowcharts and specifications.
📊 Manual Specifications
File Format
Format Type:
PDF
Searchability:
Likely text-searchable due to PDF format, enabling quick information retrieval.
Print Quality
Resolution:
Variable, but typically optimized for clarity of text, diagrams, and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1:
3.0L V6 (Mitsubishi 6G72 SOHC)
Engine 1 Power:
Approx. 150 hp @ 5000 rpm
Engine 1 Torque:
Approx. 180 lb-ft @ 3000 rpm
Engine 2:
3.3L V6 (Chrysler EBB OHV)
Engine 2 Power:
Approx. 158 hp @ 4500 rpm
Engine 2 Torque:
Approx. 195 lb-ft @ 3200 rpm
Engine 3:
3.8L V6 (Chrysler EGG OHV)
Engine 3 Power:
Approx. 166 hp @ 4400 rpm
Engine 3 Torque:
Approx. 227 lb-ft @ 3200 rpm
Fuel System
Injection Type:
Multi-port Fuel Injection (MPI) for all V6 engines.
Fuel Type:
Unleaded Gasoline (87 octane recommended)
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic Transaxle (Chrysler 41TE/42LE)
Optional
Transmission Type Optional:
All-Wheel Drive (AWD) system integrated with the 4-speed automatic transaxle on select models.
Features
Transmission Fluid Spec:
ATF+3 (Mopar)
📐 Dimensions
Exterior
Wheelbase:
Approx. 112.3 inches (2852 mm)
Length:
Approx. 189.4 inches (4811 mm)
Width:
Approx. 74.0 inches (1880 mm)
Height:
Approx. 68.7 inches (1745 mm)
Cargo
Cargo Volume Behind 1St Row:
Approx. 140.5 cu ft (4000 L)
Cargo Volume Behind 2Nd Row:
Approx. 83.5 cu ft (2364 L)
Weights
Curb Weight Min:
Approx. 3700 lbs (1678 kg)
Curb Weight Max:
Approx. 4200 lbs (1905 kg) for AWD models
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (for certain model years/configurations)
NHTSA Front Impact Passenger:
4 Stars (for certain model years/configurations)
IIHS Side Impact:
Acceptable (varies by year and equipment)
Active Features
ABS:
Standard on most models, optional on some early trims.
Traction Control:
Optional on select models, particularly AWD variants.
Passive Features
Airbags:
Driver and front passenger airbags standard. Optional side airbags became available on later models.
Seat Belts:
Three-point belts for all seating positions, with front pretensioners.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and CD player options. Premium Infinity sound systems were available on higher trims.
Navigation:
Factory-installed GPS navigation systems were optional on later models.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Auxiliary Input:
Not typically equipped with standard aux inputs; aftermarket solutions may be required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 to 7,500 miles (5,000 to 12,000 km) depending on oil type and driving conditions. Consult manual for specific recommendations.
Transmission Fluid Change Interval:
Every 30,000 to 60,000 miles (50,000 to 100,000 km) for the automatic transmission. ATF+3 fluid is critical.
Spark Plug Replacement Interval:
Every 30,000 to 100,000 miles (50,000 to 160,000 km) depending on spark plug type (conventional, platinum, iridium).
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-30 is common for most V6 engines, consult manual for specific viscosity based on ambient temperature.
Coolant Type:
Chrysler/Mopar Antifreeze/Coolant (Ethylene Glycol based, OAT or HOAT).
Brake Fluid Type:
DOT 3
Known Issues
Engine Issues:
Head gasket leaks (especially 3.3L/3.8L), intake manifold gasket leaks, oil leaks, distributor cap/rotor wear, occasional oil filter housing leaks.
Transmission Issues:
Input clutch drum failure (common in 41TE/42LE transmissions), torque converter shudder, solenoid issues, occasional failure of the power transfer unit (PTU) in AWD models.
Electrical Issues:
Instrument cluster failure (often due to faulty capacitors), power window/lock failures, faulty blend door actuators in HVAC, ABS sensor failures, PCM/ECM failures.
Suspension Chassis Issues:
Wear in ball joints and tie rod ends, sagging rear springs, front strut/shock absorber failure, exhaust system rust and leaks.
📚 Vehicle History
Brand Heritage
Parent Company:
Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles).
Model Evolution
Generation Period:
1996-2003. This generation introduced a significant redesign with improved aerodynamics, a more modern interior, and updated powertrains.
Facelifts:
Minor updates and trim changes occurred throughout the production run, but no major mid-cycle refreshes were extensive.
Production
Manufacturing Locations:
Primarily Windsor, Ontario, Canada; St. Louis, Missouri, USA; and Saltillo, Mexico.
Sales Volume:
The Chrysler Voyager and its Dodge/Plymouth siblings were consistently among the best-selling minivans in North America during this period.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
While the Voyager nameplate itself might not have consistently made 10Best lists, the minivan segment it competed in was a focus for these awards, with competitors frequently recognized.
Ratings
Consumer Reports:
Consumer Reports ratings varied significantly by model year and engine, with some years receiving average or below-average marks for reliability, particularly in transmission and electrical systems.
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