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Chrysler Voyager 1996 1997 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Model Generation: Second Generation (NS/ES) Production Years Covered By Manual: 1996, 1997 Codes Chassis Code: NS Platform: Chrysler NS platform 👋 Introduction Market Position Vehicle Segment: Minivan Target Demographic: Families, individuals needing flexible passenger and cargo space Competitive Analysis Key Competitors 1996-1997: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Plymouth Voyager (related platform) Key Features Vehicle Design Philosophy: Front-wheel drive unibody construction, emphasis on interior space and versatility Manual Value Proposition: Provides factory-level repair and maintenance information, enabling cost-effective ownership and high-quality repairs 📋 Manual Details Coverage Areas Primary Markets: North America (USA, Canada, Mexico) Specific Regions: USA, Canada, Mexico (differences noted where applicable) Page Count Estimated Page Count: 1000-1500+ (typical for comprehensive factory-style manuals) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: Digital (PDF expected) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, starting, charging systems Transmission: Automatic transmission (e.g., 41TE, 42LE) mechanical and hydraulic control, shift linkage Drivetrain: Front-wheel drive, drive shafts, CV joints, differential Suspension: Front and rear suspension components, struts, springs, bushings, alignment specifications Steering: Power steering system, steering gear, tie rods, steering column Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), hydraulic system, parking brake Electrical: Battery, charging system, starting system, lighting, instrumentation, body electrical, wiring diagrams HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, diagnosis, and repair Body: Body structure, exterior trim, interior trim, doors, windows, seats, glass replacement Chassis: Frame, body mounting, corrosion protection Safety Systems: Airbags, seat belts, ABS (as applicable) Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement, belt replacement Troubleshooting: Diagnostic procedures for all major systems, fault code interpretation (OBD-II) Repair: Component removal, installation, adjustment, and overhaul for engine, transmission, brakes, suspension, steering, electrical systems, etc. Diagnostics: Detailed diagnostic trees, circuit diagrams, and testing procedures for electrical and mechanical systems Specifications: Torque specifications, clearances, fluid capacities, component measurements Technical Depth Depth Of Coverage: Comprehensive (includes full rebuild procedures, detailed diagnostics, and complex system repairs) Audience: Professional mechanics and experienced DIY enthusiasts 📊 Manual Specifications File Format Digital File Type: PDF (Portable Document Format) - typically searchable and printable Print Quality Digital Resolution: High-resolution, suitable for on-screen viewing and printing Binding Type Physical Format If Applicable: N/A (Digital) Paper Type Physical Format If Applicable: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type 1: 3.0L SOHC V6 (EGA) Displacement 1: 2972 cc (181.4 cubic inches) Bore X Stroke 1: 91.0 mm x 76.2 mm (3.58 in x 3.00 in) Compression Ratio 1: 8.9:1 Horsepower 1 Approx: 150-158 hp @ 5200-5300 rpm (depending on year and specific calibration) Torque 1 Approx: 180-188 lb-ft @ 3200-4000 rpm (depending on year and specific calibration) Performance Fuel Type: Unleaded Gasoline Fuel System Fuel Delivery 1: Multi-port Electronic Fuel Injection (MPI) Engine Cooling Cooling System Type: Pressurized liquid cooling system Engine Lubrication Oil Type Recommendation: API SG or SH, SAE 5W-30 (check manual for exact viscosity for climate) 🔧 Transmission Standard Transmission Type Standard: 4-speed Automatic Transaxle (e.g., 41TE, 42LE) Optional Transmission Type Optional: None typically offered for this model year in this configuration Features Transmission Features: Electronically controlled, torque converter lock-up, 'Power' and 'Economy' shift modes Fluid Specifications Transmission Fluid Type: ATF+3 (Chrysler Specification) Fluid Capacities Transmission Fluid Capacity Approx: Approx. 8.0 - 9.0 quarts (7.6 - 8.5 liters) with converter (check manual) 📐 Dimensions Exterior Wheelbase: Approx. 112.1 inches (2847 mm) Length: Approx. 178.3 inches (4529 mm) Width: Approx. 72.0 inches (1829 mm) Height: Approx. 67.9 inches (1725 mm) Cargo Cargo Volume Behind 3Rd Row Approx: Approx. 15.5 - 19.0 cubic feet (depending on configuration) Cargo Volume With 3Rd Row Folded Approx: Approx. 40.0 - 47.0 cubic feet Weights Curb Weight Approx: Approx. 3800 - 4000 lbs (1724 - 1814 kg) Gross Vehicle Weight Rating Gvwr Approx: Approx. 5200 - 5500 lbs (2359 - 2495 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Acceptable (for 1996 models) NHTSA Front Impact Passenger: Acceptable (for 1996 models) IIHS Side Impact: Acceptable (for 1996 models) Active Features ABS: Standard on most trims, optional on some earlier configurations Passive Features Airbags: Driver and passenger front airbags Seat Belts: Three-point seat belts for all occupants, front pretensioners Child Safety Features: LATCH anchors (introduced in later years, check specific vehicle) 💡 Technology Features Infotainment Audio System Options: AM/FM stereo with cassette, optional CD player, speaker configurations varied by trim Driver Assistance Cruise Control: Standard or optional depending on trim level Anti Lock Braking System ABS: Available, enhances braking control during hard stops Connectivity Diagnostic Interface: OBD-II (On-Board Diagnostics II) port, enabling modern scan tool diagnostics 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions) Transmission...
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Chrysler Voyager 1996 1997 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Model Generation:
Second Generation (NS/ES)
Production Years Covered By Manual:
1996, 1997
Codes
Chassis Code:
NS
Platform:
Chrysler NS platform
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Demographic:
Families, individuals needing flexible passenger and cargo space
Competitive Analysis
Key Competitors 1996-1997:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Plymouth Voyager (related platform)
Key Features
Vehicle Design Philosophy:
Front-wheel drive unibody construction, emphasis on interior space and versatility
Manual Value Proposition:
Provides factory-level repair and maintenance information, enabling cost-effective ownership and high-quality repairs
📋 Manual Details
Coverage Areas
Primary Markets:
North America (USA, Canada, Mexico)
Specific Regions:
USA, Canada, Mexico (differences noted where applicable)
Page Count
Estimated Page Count:
1000-1500+ (typical for comprehensive factory-style manuals)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF expected)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, starting, charging systems
Transmission:
Automatic transmission (e.g., 41TE, 42LE) mechanical and hydraulic control, shift linkage
Drivetrain:
Front-wheel drive, drive shafts, CV joints, differential
Suspension:
Front and rear suspension components, struts, springs, bushings, alignment specifications
Steering:
Power steering system, steering gear, tie rods, steering column
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), hydraulic system, parking brake
Electrical:
Battery, charging system, starting system, lighting, instrumentation, body electrical, wiring diagrams
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components, diagnosis, and repair
Body:
Body structure, exterior trim, interior trim, doors, windows, seats, glass replacement
Chassis:
Frame, body mounting, corrosion protection
Safety Systems:
Airbags, seat belts, ABS (as applicable)
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement, belt replacement
Troubleshooting:
Diagnostic procedures for all major systems, fault code interpretation (OBD-II)
Repair:
Component removal, installation, adjustment, and overhaul for engine, transmission, brakes, suspension, steering, electrical systems, etc.
Diagnostics:
Detailed diagnostic trees, circuit diagrams, and testing procedures for electrical and mechanical systems
Specifications:
Torque specifications, clearances, fluid capacities, component measurements
Technical Depth
Depth Of Coverage:
Comprehensive (includes full rebuild procedures, detailed diagnostics, and complex system repairs)
Audience:
Professional mechanics and experienced DIY enthusiasts
📊 Manual Specifications
File Format
Digital File Type:
PDF (Portable Document Format) - typically searchable and printable
Print Quality
Digital Resolution:
High-resolution, suitable for on-screen viewing and printing
Binding Type
Physical Format If Applicable:
N/A (Digital)
Paper Type
Physical Format If Applicable:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
3.0L SOHC V6 (EGA)
Displacement 1:
2972 cc (181.4 cubic inches)
Bore X Stroke 1:
91.0 mm x 76.2 mm (3.58 in x 3.00 in)
Compression Ratio 1:
8.9:1
Horsepower 1 Approx:
150-158 hp @ 5200-5300 rpm (depending on year and specific calibration)
Torque 1 Approx:
180-188 lb-ft @ 3200-4000 rpm (depending on year and specific calibration)
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Fuel Delivery 1:
Multi-port Electronic Fuel Injection (MPI)
Engine Cooling
Cooling System Type:
Pressurized liquid cooling system
Engine Lubrication
Oil Type Recommendation:
API SG or SH, SAE 5W-30 (check manual for exact viscosity for climate)
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic Transaxle (e.g., 41TE, 42LE)
Optional
Transmission Type Optional:
None typically offered for this model year in this configuration
Features
Transmission Features:
Electronically controlled, torque converter lock-up, 'Power' and 'Economy' shift modes
Fluid Specifications
Transmission Fluid Type:
ATF+3 (Chrysler Specification)
Fluid Capacities
Transmission Fluid Capacity Approx:
Approx. 8.0 - 9.0 quarts (7.6 - 8.5 liters) with converter (check manual)
📐 Dimensions
Exterior
Wheelbase:
Approx. 112.1 inches (2847 mm)
Length:
Approx. 178.3 inches (4529 mm)
Width:
Approx. 72.0 inches (1829 mm)
Height:
Approx. 67.9 inches (1725 mm)
Cargo
Cargo Volume Behind 3Rd Row Approx:
Approx. 15.5 - 19.0 cubic feet (depending on configuration)
Cargo Volume With 3Rd Row Folded Approx:
Approx. 40.0 - 47.0 cubic feet
Weights
Curb Weight Approx:
Approx. 3800 - 4000 lbs (1724 - 1814 kg)
Gross Vehicle Weight Rating Gvwr Approx:
Approx. 5200 - 5500 lbs (2359 - 2495 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Acceptable (for 1996 models)
NHTSA Front Impact Passenger:
Acceptable (for 1996 models)
IIHS Side Impact:
Acceptable (for 1996 models)
Active Features
ABS:
Standard on most trims, optional on some earlier configurations
Passive Features
Airbags:
Driver and passenger front airbags
Seat Belts:
Three-point seat belts for all occupants, front pretensioners
Child Safety Features:
LATCH anchors (introduced in later years, check specific vehicle)
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with cassette, optional CD player, speaker configurations varied by trim
Driver Assistance
Cruise Control:
Standard or optional depending on trim level
Anti Lock Braking System ABS:
Available, enhances braking control during hard stops
Connectivity
Diagnostic Interface:
OBD-II (On-Board Diagnostics II) port, enabling modern scan tool diagnostics
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions)
Transmission Fluid Change Interval:
Every 30,000-60,000 miles (48,000-96,000 km), depending on service classification and driving conditions (refer to manual)
Engine Coolant Change Interval:
Every 30,000 miles (48,000 km) or 24 months (use Mopar OAT or equivalent)
Spark Plug Replacement Interval:
Approx. 100,000 miles (160,000 km) with platinum-tipped spark plugs
Fluid Specifications
Engine Coolant Type:
Mopar Organic Acid Technology (OAT) Antifreeze/Coolant or equivalent (typically HOAT for this era)
Brake Fluid Type:
DOT 3
Fluid Capacities
Engine Oil Capacity Approx:
4.0 quarts (3.8 liters) with filter (for 3.0L V6)
Cooling System Capacity Approx:
Approx. 10.0 - 11.0 quarts (9.5 - 10.4 liters)
Known Issues
Common Issue 1:
Transmission solenoid pack failure (especially 41TE/42LE)
Common Issue 2:
EGR (Exhaust Gas Recirculation) valve clogging leading to rough idle or stalling
Common Issue 3:
Power window regulator failure
Common Issue 4:
Cracked dashboard (particularly the upper section exposed to sunlight)
Common Issue 5:
Door lock actuator failure
Common Issue 6:
Water pump seal leaks
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984.
Model Evolution
Ns Generation Introduction:
The second generation (NS) was introduced for the 1996 model year, featuring a more aerodynamic design, improved interior, and updated powertrains.
Distinction From Dodge Plymouth:
The Chrysler Voyager in this generation was positioned as a slightly more premium offering compared to its Dodge Caravan and Plymouth Voyager counterparts, often with different trim levels and feature packaging.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Chrysler minivans (including the platform this represents) were frequent recipients of Car and Driver's 10Best list in previous generations, setting benchmarks for the segment.
Ratings
Consumer Reports Historical Ratings:
Consumer Reports ratings for this generation were generally average to below average, particularly concerning reliability in some areas. The manual is crucial for addressing these potential issues.
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