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Chrysler Voyager 1999 All Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 1999 Generation Generation Code: NS Codes Chassis Code: GS 👋 Introduction Market Position Segment: Mid-size Minivan Target Audience: Families, individuals needing versatile cargo and passenger capacity. Competitive Analysis Key Competitors 1999: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, Buick GL8 Key Features Design Philosophy: Practical, family-oriented, spacious interior, comfortable ride. Distinguishing Features: Optional Stow 'n Go seating (introduced later, but the platform was evolving), good cargo volume, comfortable seating arrangements. Manual Purpose Purpose: To provide detailed repair and maintenance information for the 1999 Chrysler Voyager, enabling owners and technicians to perform diagnostics, repairs, and maintenance accurately and efficiently. 📋 Manual Details Coverage Areas Markets Covered: North America, Europe (Chrysler Voyager/Dodge Caravan variants) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: 2.4L DOHC I4 (EDZ), 3.0L V6 SOHC (6G72 - Mitsubishi), 3.3L V6 OHV (EGA), 3.8L V6 OHV (EVE/EVB) Transmission: Automatic Transmissions (A604/41TE, A670/42LE, A670/42RLE) Drivetrain: Front-Wheel Drive (FWD) Suspension: Front Independent MacPherson Struts, Rear Solid Axle with Leaf Springs Brakes: Front Ventilated Discs, Rear Drums; ABS System Steering: Power Assisted Rack and Pinion Electrical: Complete Wiring Diagrams, Fuses, Relays, Lighting, Ignition, Charging System, Starting System HVAC: Heating, Ventilation, Air Conditioning System Diagnosis and Repair Body: Exterior Body Panels, Interior Trim, Doors, Windows, Locks, Seats Safety Systems: Airbags, Seatbelts, ABS Functionality Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Fluid Replacements, Filter Replacements, Spark Plug Replacement Engine Repair: Engine Removal/Installation, Cylinder Head Removal/Installation, Piston/Ring Replacement, Valve Adjustment, Timing Belt/Chain Service Transmission Repair: Transmission Fluid Change, Torque Converter Replacement, Valve Body Service, Clutch Pack Service (where applicable), Transmission Rebuild Procedures Brake Service: Brake Pad/Shoe Replacement, Rotor/Drum Resurfacing/Replacement, Brake Fluid Flush, ABS Component Diagnosis and Replacement Suspension Steering Service: Strut Replacement, Ball Joint Replacement, Tie Rod End Replacement, Power Steering Pump/Rack Replacement Electrical Diagnostics: Troubleshooting Faulty Circuits, Component Testing, Wiring Harness Repair HVAC Repair: Component Replacement (Compressor, Evaporator, Condenser), Refrigerant Servicing, Blower Motor Replacement Body Repair: Panel Alignment, Door Mechanism Repair, Glass Replacement, Trim Piece Installation Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Guides Technical Depth Depth: Comprehensive; Covers everything from basic fluid checks and routine maintenance to in-depth engine and transmission overhauls, electrical system diagnostics, and bodywork. Diagnostic Capability: Includes procedures for diagnosing and repairing issues using factory specifications and recommended tools. Rebuild Instructions: Detailed rebuild procedures for major components like engines and transmissions, including torque specifications and clearances. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Quality: High-resolution scans or original digital files, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Compatibility Device Compatibility: Viewable on any device with a PDF reader (PC, Mac, Tablet, Smartphone). ⚙️ Engine Specifications Primary Engine Engine Option 1: 2.4L DOHC I4 (EDZ) Engine Option 1 Displacement: 2429 cc Engine Option 1 Power: 150 hp @ 5800 rpm Engine Option 1 Torque: 170 lb-ft @ 4400 rpm Engine Option 2: 3.0L V6 SOHC (Mitsubishi 6G72) Engine Option 2 Displacement: 2972 cc Engine Option 2 Power: 153 hp @ 5250 rpm Engine Option 2 Torque: 179 lb-ft @ 4000 rpm Engine Option 3: 3.3L V6 OHV (EGA) Engine Option 3 Displacement: 3301 cc Engine Option 3 Power: 156 hp @ 4700 rpm Engine Option 3 Torque: 201 lb-ft @ 3600 rpm Engine Option 4: 3.8L V6 OHV (EVE/EVB) Engine Option 4 Displacement: 3778 cc Engine Option 4 Power: 180 hp @ 4700 rpm Engine Option 4 Torque: 235 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Recommended Octane: 87 Octane (check vehicle sticker/manual for specifics) 🔧 Transmission Standard Standard Transmission: 4-Speed Automatic Optional Optional Transmission: N/A (All models equipped with automatic) Features Transmission Codes: A604/41TE (FWD), A670/42LE, A670/42RLE (some models) Transmission Fluid Type: ATF+4 (Chrysler Automatic Transmission Fluid Type 4) - Recommended, though original spec may have been ATF+3 or Dexron III. Verify with manual for exact fill. Transmission Fluid Capacity: Approximately 8-9 quarts (8.5-9.5 liters) for a dry fill (consult manual for exact capacities). 📐 Dimensions Exterior Wheelbase: 112.1 inches (2847 mm) Length: 193.0 inches (4890 mm) Width: 76.7 inches (1948 mm) Height: 68.3 inches (1735 mm) Interior Seating Capacity: 7 passengers (2-2-3 configuration typically) Cargo Cargo Volume Behind 3Rd Row: Approx. 15-20 cu ft (varies slightly by configuration) Cargo Volume Behind 2Nd Row: Approx. 45-50 cu ft Cargo Volume With All Seats Folded: Approx. 110-120 cu ft Weights Curb Weight Base Model: Approx. 3700-3900 lbs (1678-1769 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5100-5400 lbs (2313-2449 kg) 🛡️ Safety Features Ratings NHTSA Front Crash Test Driver: 4-star (likely, based on similar vehicles of the era -...
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🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Year:
1999
Generation
Generation Code:
NS
Codes
Chassis Code:
GS
👋 Introduction
Market Position
Segment:
Mid-size Minivan
Target Audience:
Families, individuals needing versatile cargo and passenger capacity.
Competitive Analysis
Key Competitors 1999:
Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, Buick GL8
Key Features
Design Philosophy:
Practical, family-oriented, spacious interior, comfortable ride.
Distinguishing Features:
Optional Stow 'n Go seating (introduced later, but the platform was evolving), good cargo volume, comfortable seating arrangements.
Manual Purpose
Purpose:
To provide detailed repair and maintenance information for the 1999 Chrysler Voyager, enabling owners and technicians to perform diagnostics, repairs, and maintenance accurately and efficiently.
📋 Manual Details
Coverage Areas
Markets Covered:
North America, Europe (Chrysler Voyager/Dodge Caravan variants)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
2.4L DOHC I4 (EDZ), 3.0L V6 SOHC (6G72 - Mitsubishi), 3.3L V6 OHV (EGA), 3.8L V6 OHV (EVE/EVB)
Transmission:
Automatic Transmissions (A604/41TE, A670/42LE, A670/42RLE)
Drivetrain:
Front-Wheel Drive (FWD)
Suspension:
Front Independent MacPherson Struts, Rear Solid Axle with Leaf Springs
Brakes:
Front Ventilated Discs, Rear Drums; ABS System
Steering:
Power Assisted Rack and Pinion
Electrical:
Complete Wiring Diagrams, Fuses, Relays, Lighting, Ignition, Charging System, Starting System
HVAC:
Heating, Ventilation, Air Conditioning System Diagnosis and Repair
Body:
Exterior Body Panels, Interior Trim, Doors, Windows, Locks, Seats
Safety Systems:
Airbags, Seatbelts, ABS Functionality
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Fluid Replacements, Filter Replacements, Spark Plug Replacement
Engine Repair:
Engine Removal/Installation, Cylinder Head Removal/Installation, Piston/Ring Replacement, Valve Adjustment, Timing Belt/Chain Service
Transmission Repair:
Transmission Fluid Change, Torque Converter Replacement, Valve Body Service, Clutch Pack Service (where applicable), Transmission Rebuild Procedures
Brake Service:
Brake Pad/Shoe Replacement, Rotor/Drum Resurfacing/Replacement, Brake Fluid Flush, ABS Component Diagnosis and Replacement
Suspension Steering Service:
Strut Replacement, Ball Joint Replacement, Tie Rod End Replacement, Power Steering Pump/Rack Replacement
Electrical Diagnostics:
Troubleshooting Faulty Circuits, Component Testing, Wiring Harness Repair
HVAC Repair:
Component Replacement (Compressor, Evaporator, Condenser), Refrigerant Servicing, Blower Motor Replacement
Body Repair:
Panel Alignment, Door Mechanism Repair, Glass Replacement, Trim Piece Installation
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Guides
Technical Depth
Depth:
Comprehensive; Covers everything from basic fluid checks and routine maintenance to in-depth engine and transmission overhauls, electrical system diagnostics, and bodywork.
Diagnostic Capability:
Includes procedures for diagnosing and repairing issues using factory specifications and recommended tools.
Rebuild Instructions:
Detailed rebuild procedures for major components like engines and transmissions, including torque specifications and clearances.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Quality:
High-resolution scans or original digital files, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Compatibility
Device Compatibility:
Viewable on any device with a PDF reader (PC, Mac, Tablet, Smartphone).
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
2.4L DOHC I4 (EDZ)
Engine Option 1 Displacement:
2429 cc
Engine Option 1 Power:
150 hp @ 5800 rpm
Engine Option 1 Torque:
170 lb-ft @ 4400 rpm
Engine Option 2:
3.0L V6 SOHC (Mitsubishi 6G72)
Engine Option 2 Displacement:
2972 cc
Engine Option 2 Power:
153 hp @ 5250 rpm
Engine Option 2 Torque:
179 lb-ft @ 4000 rpm
Engine Option 3:
3.3L V6 OHV (EGA)
Engine Option 3 Displacement:
3301 cc
Engine Option 3 Power:
156 hp @ 4700 rpm
Engine Option 3 Torque:
201 lb-ft @ 3600 rpm
Engine Option 4:
3.8L V6 OHV (EVE/EVB)
Engine Option 4 Displacement:
3778 cc
Engine Option 4 Power:
180 hp @ 4700 rpm
Engine Option 4 Torque:
235 lb-ft @ 3600 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 Octane (check vehicle sticker/manual for specifics)
🔧 Transmission
Standard
Standard Transmission:
4-Speed Automatic
Optional
Optional Transmission:
N/A (All models equipped with automatic)
Features
Transmission Codes:
A604/41TE (FWD), A670/42LE, A670/42RLE (some models)
Transmission Fluid Type:
ATF+4 (Chrysler Automatic Transmission Fluid Type 4) - Recommended, though original spec may have been ATF+3 or Dexron III. Verify with manual for exact fill.
Transmission Fluid Capacity:
Approximately 8-9 quarts (8.5-9.5 liters) for a dry fill (consult manual for exact capacities).
📐 Dimensions
Exterior
Wheelbase:
112.1 inches (2847 mm)
Length:
193.0 inches (4890 mm)
Width:
76.7 inches (1948 mm)
Height:
68.3 inches (1735 mm)
Interior
Seating Capacity:
7 passengers (2-2-3 configuration typically)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 15-20 cu ft (varies slightly by configuration)
Cargo Volume Behind 2Nd Row:
Approx. 45-50 cu ft
Cargo Volume With All Seats Folded:
Approx. 110-120 cu ft
Weights
Curb Weight Base Model:
Approx. 3700-3900 lbs (1678-1769 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5100-5400 lbs (2313-2449 kg)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Driver:
4-star (likely, based on similar vehicles of the era - exact rating for 1999 NS Voyager may vary and requires specific testing documentation)
NHTSA Front Crash Test Passenger:
4-star (likely)
IIHS Offset Frontal Crash Rating:
Acceptable (for vehicles of this generation)
Active Features
ABS:
Standard on most trims, Optional on base trims.
Traction Control:
Optional on higher trims
Passive Features
Airbags:
Driver and Front Passenger Airbags (Standard)
Seat Belts:
3-point seat belts in all seating positions, front seat belt pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or optional CD player. Speaker configurations varied by trim.
Climate Control:
Manual climate control standard, optional automatic climate control available on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Connectivity Options:
Limited by 1999 standards; primarily analog connections for audio. No integrated Bluetooth or USB typically found.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (4,800-12,000 km) or 6-12 months, depending on oil type and driving conditions. Consult manual for specific recommendations.
Engine Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km) or 3 years, especially under severe usage. Critical for longevity of these transmissions.
Spark Plug Replacement 2.4L:
Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.
Spark Plug Replacement V6:
Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.
Timing Belt Replacement:
Not applicable for the 2.4L DOHC (chain-driven). V6 engines (3.0L, 3.3L, 3.8L) are also typically chain-driven for this generation, but manual confirmation is advised.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 10W-30 (depending on climate and engine, consult manual). API certified.
Engine Oil Capacity 2.4L:
Approx. 4.5 quarts (4.3 liters) with filter.
Engine Oil Capacity 3.3L/3.8L V6:
Approx. 4.5 quarts (4.3 liters) with filter.
Engine Oil Capacity 3.0L V6:
Approx. 4.5 quarts (4.3 liters) with filter.
Brake Fluid Specification:
DOT 3 or DOT 4 (check cap/manual)
Known Issues
Common Issue 1:
Transmission failure (especially A604/41TE transmission solenoid issues, torque converter problems, and fluid leaks).
Common Issue 2:
Cooling system leaks (radiator, heater core, hoses).
Common Issue 3:
Power window and lock failures, often due to faulty switches or regulator mechanisms.
Common Issue 4:
Ignition system issues (e.g., coil packs, spark plug wires).
Common Issue 5:
CV axle wear and failure.
Common Issue 6:
Door latch and sliding door mechanism issues.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment in the US with the original Dodge Caravan and Plymouth Voyager in 1984, setting the standard for family vehicles.
Model Evolution
Ns Generation Introduction:
The NS generation Voyager (and its Dodge Caravan/Plymouth Voyager siblings) was introduced for the 1996 model year, representing a significant redesign from the previous RS generation.
Year 1999 Updates:
For 1999, the Voyager received minor updates, including revised option packages and potentially some feature shuffling between trim levels. The core platform and powertrain options remained largely consistent with prior NS models.
Production
Production Location:
Windsor, Ontario, Canada (Chrysler Canada's assembly plant)
Production Years Ns Generation:
1996-2000
🏆 Awards & Recognition
Recognitions
Minivan Awards General:
Chrysler minivans (Voyager, Caravan) have historically been well-regarded for their practicality and innovation in the segment, frequently appearing on 'Best Family Car' lists and similar accolades throughout the 1990s.