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Chrysler Voyager 1996-2003 All Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Production Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Codes Platform: NS/GS (Long wheelbase variant of the Dodge Caravan/Plymouth Voyager)...
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Chrysler Voyager 1996-2003 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Codes
Platform:
NS/GS (Long wheelbase variant of the Dodge Caravan/Plymouth Voyager)
👋 Introduction
Market Position
Segment:
Full-size Minivan
Competitive Analysis
Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Montana, Honda Odyssey, Toyota Sienna
Key Features
Features:
Spacious interior, versatile seating configurations, comfortable ride, strong towing capacity for its class.
Manual Value Proposition
Value:
Empowers DIY mechanics with detailed, accurate information to maintain and repair their Chrysler Voyager effectively, saving on labor costs.
📋 Manual Details
Coverage Areas
Coverage:
All Service and Repair
Page Count
Estimated Page Count:
2000+
Manual Type
Type:
Comprehensive Service & Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
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
Procedures Included
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
Technical Depth
Depth:
Comprehensive: Covers basic maintenance, routine service, advanced diagnostics, and complete component overhaul/rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1:
3.3L V6 (3301cc)
Engine 1 Code:
EGA
Engine 1 Performance Hp:
Approx. 158 hp @ 4700 rpm
Engine 1 Performance Torque:
Approx. 190 lb-ft @ 3300 rpm
Optional Engine
Engine 2:
3.8L V6 (3778cc)
Engine 2 Code:
L32
Engine 2 Performance Hp:
Approx. 180 hp @ 4700 rpm
Engine 2 Performance Torque:
Approx. 235 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Engine Management
ECM:
Chrysler NGC (Next Generation Controller) or similar
Emission Control
Emission Systems:
Catalytic converter, EGR valve, O2 sensors, EVAP system
🔧 Transmission
Standard Transmission
Type 1:
4-Speed Automatic
Code 1:
A604 / 41TE (Ultradrive)
Optional Transmission
Type 2:
N/A (Only automatic was prevalent for these years)
Features
Transmission Features:
Electronically controlled, Torque converter lock-up, Selectable low gear
Fluid Specifications
Transmission Fluid:
ATF+4 (or equivalent ATF that meets Chrysler MS-9602 specifications)
Fluid Capacity
Capacity Liters:
Approx. 4.5-5.5 liters (pan drop)
📐 Dimensions
Exterior
Wheelbase Mm:
3032 (119.4 inches)
Length Mm:
4747 (186.9 inches)
Width Mm:
1788 (70.4 inches)
Height Mm:
1750 (68.9 inches)
Weights
Curb Weight Kg:
Approx. 1800-1950 kg (depending on configuration)
Cargo
Cargo Volume Liters:
Approx. 1470 - 4000+ liters (with rear seats removed/folded)
Towing
Towing Capacity Kg:
Approx. 1633 kg (3600 lbs) with optional towing package
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Rating:
4 Stars (for models with driver-side airbag)
NHTSA Frontal Passenger Rating:
4 Stars (for models with passenger-side airbag)
Active Features
ABS:
Standard on most models, optional on some earlier trims
Passive Features
Airbags:
Driver and front passenger airbags standard (optional side airbags on later models)
Seatbelts:
3-point seatbelts in all seating positions, front seatbelt pretensioners
💡 Technology Features
Infotainment
Audio Systems:
AM/FM stereo with cassette and CD player options, available Infinity sound systems.
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Power Features:
Power windows, power door locks, power mirrors (availability varies by trim level).
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
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
Known Issues
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.
Parts Guidance
Filter Part Numbers:
Refer to manual for specific part numbers for oil filters, air filters, cabin filters, and transmission filters.
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler Corporation, known for pioneering front-wheel-drive technology and the minivan segment.
Model Evolution
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.
Production
Manufacturing Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for this model year are not widely publicized, the Chrysler Voyager/Town & Country platform consistently ranked high in family vehicle and minivan categories during its production run.
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