Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Platform:
NS/GS (Long wheelbase variant of the Dodge Caravan/Plymouth Voyager)
Segment:
Full-size Minivan
Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna
Features:
Spacious interior, versatile seating configurations, comfortable ride, strong towing capacity for its class.
Value:
Empowers DIY mechanics with detailed, accurate information to maintain and repair their Chrysler Voyager effectively, saving on labor costs.
Engine Systems:
Engine mechanicals, fuel system, ignition system, cooling system, lubrication system, exhaust system, emission control systems
Transmission Systems:
Automatic transmission (e.g., A604, 41TE) repair, service, diagnostics, fluid and filter replacement
Drivetrain Systems:
Front-wheel drive, axle shafts, differential, CV joints
Suspension And Steering:
Front and rear suspension components, steering system diagnosis and repair, power steering system
Braking Systems:
Front and rear brakes (disc/drum), ABS system diagnosis and repair, brake fluid service
Electrical Systems:
Wiring diagrams, charging system, starting system, lighting, instrument panel, body electrical components, power windows, locks, mirrors
HVAC Systems:
Heating, ventilation, and air conditioning system diagnosis, repair, refrigerant handling
Body And Interior:
Body panel repair, door mechanisms, interior trim, seating systems, glass replacement
Diagnostics:
On-board diagnostics (OBD-II) interpretation, fault code retrieval and diagnosis, troubleshooting guides
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, coolant flushes, brake inspections, tire rotations
Repair Procedures:
Engine component replacement (e.g., alternator, starter, water pump), transmission service, brake caliper replacement, suspension arm replacement
Troubleshooting Guides:
Step-by-step diagnostics for common drivability issues, electrical faults, and mechanical problems
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems
Depth:
Comprehensive: Covers basic maintenance, routine service, advanced diagnostics, and complete component overhaul/rebuilds.
Engine 1:
3.3L V6 (3301cc)
Engine 1 Performance Hp:
Approx. 158 hp @ 4700 rpm
Engine 1 Performance Torque:
Approx. 190 lb-ft @ 3300 rpm
Engine 2:
3.8L V6 (3778cc)
Engine 2 Performance Hp:
Approx. 180 hp @ 4700 rpm
Engine 2 Performance Torque:
Approx. 235 lb-ft @ 3200 rpm
Fuel Delivery:
Multi-port Fuel Injection (MPI)
ECM:
Chrysler NGC (Next Generation Controller) or similar
Emission Systems:
Catalytic converter, EGR valve, O2 sensors, EVAP system
Type 1:
4-Speed Automatic
Code 1:
A604 / 41TE (Ultradrive)
Type 2:
N/A (Only automatic was prevalent for these years)
Transmission Features:
Electronically controlled, Torque converter lock-up, Selectable low gear
Transmission Fluid:
ATF+4 (or equivalent ATF that meets Chrysler MS-9602 specifications)
Capacity Liters:
Approx. 4.5-5.5 liters (pan drop)
NHTSA Frontal Driver Rating:
4 Stars (for models with driver-side airbag)
NHTSA Frontal Passenger Rating:
4 Stars (for models with passenger-side airbag)
ABS:
Standard on most models, optional on some earlier trims
Airbags:
Driver and front passenger airbags standard (optional side airbags on later models)
Seatbelts:
3-point seatbelts in all seating positions, front seatbelt pretensioners
Oil Change Interval Km:
Every 8,000 - 12,000 km (5,000 - 7,500 miles) or 6 months, whichever comes first (depending on driving conditions and oil type).
Transmission Fluid Change Interval Km:
Every 50,000 - 80,000 km (30,000 - 50,000 miles) or 3 years, whichever comes first.
Coolant Flush Interval Km:
Every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5 years.
Engine Oil Specification:
SAE 5W-30 or 10W-30 (refer to owner's manual for exact viscosity based on ambient temperature)
Coolant Specification:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant (typically pink or orange color), or a compatible antifreeze/water mixture.
Brake Fluid Specification:
DOT 3
Common Problems 1:
Transmission solenoid issues, torque converter shudder, CV joint wear, power steering pump leaks, HVAC blower motor failures, window regulator failures.
Common Problems 2:
Engine oil leaks (e.g., valve cover gaskets), catalytic converter failure, exhaust manifold leaks, ABS sensor faults.
Filter Part Numbers:
Refer to manual for specific part numbers for oil filters, air filters, cabin filters, and transmission filters.
Brand Focus:
Chrysler Corporation, known for pioneering front-wheel-drive technology and the minivan segment.
Generation:
Second Generation (NS/GS), which ran from 1996-2000, and the Third Generation (RS) from 2001-2007. This manual covers the transition and includes details for both.
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA