Positioning:
The Chrysler Voyager was a cornerstone of the minivan segment, offering practicality, space, and comfort for families. This manual caters to owners and independent repair facilities looking to maintain and repair these popular vehicles.
Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Oldsmobile Silhouette, Toyota Sienna, Honda Odyssey.
Vehicle Strengths:
Spacious interior, flexible seating configurations (Stow 'n Go precursor), comfortable ride, and a wide array of available engines and options.
Value For Buyers:
Empowers owners to perform DIY maintenance and repairs, saving money and extending vehicle lifespan. Provides professional-grade information for independent mechanics.
Primary Markets:
North America (USA, Canada)
Specific Models Covered:
Chrysler Voyager, Dodge Caravan, Plymouth Voyager (all trim levels within the specified years)
Estimated Pages:
Approximately 1500-2000 (typical for comprehensive workshop manuals of this era)
Type:
Workshop Manual / Service Manual
Format:
Digital (PDF) / Printed (as specified by seller)
Powertrain:
Engine (2.4L DOHC, 3.0L V6 SOHC, 3.3L V6 OHV, 3.8L V6 OHV), Transmission (3-speed Automatic 31TE, 4-speed Automatic 41TE/AE), Drivetrain (FWD)
Chassis:
Suspension (Front MacPherson Strut, Rear Torsion Beam Axle), Steering (Power Rack and Pinion), Brakes (Front Disc, Rear Drum/Disc depending on trim), Wheels and Tires
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Instruments, Gauges, Power Accessories (windows, locks, seats), HVAC Controls, Radio/Audio Systems, Body Control Module (BCM)
Body And Interior:
Body Panels, Doors, Hood, Liftgate, Bumpers, Glass, Seats, Trim, HVAC System (evaporator, heater core, blower motor, ducting), Seat Belts, Airbags (SRS)
Maintenance:
Oil Changes, Filter Replacements (oil, air, fuel, cabin), Spark Plug Replacement, Coolant Flush and Fill, Brake Fluid Flush, Belt Inspection and Replacement, Wiper Blade Replacement
Repair Engine:
Engine Overhaul, Cylinder Head Removal/Installation, Piston/Connecting Rod Service, Crankshaft Service, Timing Belt/Chain Replacement (if applicable), Fuel Injector Service, EGR System Service
Repair Transmission:
Transmission Fluid and Filter Change, Transmission Removal/Installation, Torque Converter Service, Internal Transmission Component Repair (e.g., clutch packs, seals)
Diagnostics:
Troubleshooting Common Problems, Diagnostic Trouble Codes (DTCs), Electrical System Diagnostics, Fuel System Diagnostics, Emission Control System Diagnostics
Special Procedures:
Air Conditioning System Service (refrigerant handling, component replacement), Airbag System Service (deactivation/activation, component replacement), ABS System Diagnostics and Repair, Cruise Control System Service
Depth:
Comprehensive: Covers routine maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and component-level repair.
Digital Format Details:
PDF, Searchable Text, Bookmarked Chapters, High-Resolution Diagrams
Print Quality:
Professional Printing (if applicable), Clear Diagrams and Text
Binding Type:
Coil Bound / Perfect Bound (common for workshop manuals to lay flat)
Paper Type:
Heavy-duty, Glossy or Semi-gloss Paper (to withstand shop environment)
Engine 1:
2.4L DOHC Inline-4 (420 Engine)
Engine 2:
3.0L SOHC V6 (Mitsubishi 6G72)
Engine 3:
3.3L OHV V6 (EGA Engine)
Engine 4:
3.8L OHV V6 (EGH Engine)
Horsepower 2 4L:
150 hp @ 5800 rpm
Torque 2 4L:
170 lb-ft @ 4500 rpm
Horsepower 3 3L:
158 hp @ 4400 rpm (early years), 170 hp @ 4600 rpm (later years)
Torque 3 3L:
190 lb-ft @ 3200 rpm (early years), 200 lb-ft @ 3200 rpm (later years)
Horsepower 3 8L:
166 hp @ 4400 rpm (early years), 180 hp @ 4400 rpm (later years)
Torque 3 8L:
207 lb-ft @ 3200 rpm (early years), 220 lb-ft @ 3200 rpm (later years)
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Transmission Type Standard:
3-speed Automatic (31TE - typically with 2.4L and 3.0L engines)
Transmission Type Optional:
4-speed Automatic (41TE/AE - typically with 3.3L and 3.8L engines)
Transmission Features:
Electronic overdrive control, Torque converter clutch (TCC) for improved fuel economy on 4-speed units.
Fluid Type:
ATF+4 (Automatic Transmission Fluid Type 9602) recommended for 41TE/AE. ATF+3 (Type 954A) or equivalent for 31TE. Consult manual for exact specs and changes.
NHTSA Front Impact Driver:
4-star (1996-1999 models tested)
NHTSA Front Impact Passenger:
4-star (1996-1999 models tested)
NHTSA Side Impact Front:
4-star (1996-1999 models tested)
IIHS Frontal Offset:
Good (for 1996-1999 models)
ABS:
Standard on most models (4-wheel disc brakes on some higher trims and later models)
Traction Control:
Optional on some models, particularly with V6 engines.
Airbags Front:
Driver and Passenger Frontal Airbags (SRS)
Seat Belts:
Three-point seat belts for all seating positions, integrated child seat anchors (LATCH) not standard in this era.
Child Safety Locks:
Standard on rear doors.
Audio Systems:
AM/FM Stereo with Cassette and CD Player (optional), available premium Infinity sound systems.
Climate Control:
Manual Air Conditioning, Automatic Climate Control (optional on higher trims).
Cruise Control:
Standard on most models.
Keyless Entry:
Optional remote keyless entry system.
Connectivity Features:
Limited for the era; primarily focused on audio system connectivity. No integrated Bluetooth or USB ports from factory.
Oil Change Interval:
Every 7,500 miles or 6 months (under normal driving conditions). Consult manual for severe driving conditions.
Service Intervals Filters
Air Filter Replacement:
Every 30,000 miles or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000-30,000 miles or annually, depending on environment.
Coolant Flush Interval:
Every 60,000 miles or 5 years (using HOAT coolant).
Transmission Fluid Interval:
Every 30,000 miles for filter/fluid change, or 60,000 miles for fluid only (refer to manual for specific transmission type).
Engine Oil Spec:
SAE 5W-30 (API Certified). Check manual for seasonal variations or specific engine requirements.
Coolant Spec:
Chrysler Preferred Coolant (or equivalent HOAT - Hybrid Organic Acid Technology) - typically a pink/orange coolant.
Common Problem 1:
Transmission solenoid pack failure (especially 41TE/AE), leading to shifting problems.
Common Problem 2:
Power steering pump leaks or noisy pumps.
Common Problem 3:
Rattling heat shields on exhaust system.
Common Problem 4:
Alternator failures, particularly on V6 models.
Common Problem 5:
Window regulator failures, especially rear sliding windows on some trims.
Common Problem 6:
Chrysler's '1996-era' intermittent electronic issues, sometimes related to ground points or the Body Control Module (BCM).
Chrysler Minivan Legacy:
Chrysler revolutionized the automotive industry by inventing the modern minivan with the original Dodge Caravan and Plymouth Voyager in 1983. The 1996-2003 generation represents the third major redesign of this highly successful formula.
Generation Codename:
NS (1996-2000) and GS (2001-2003) platforms. Notable redesigns included smoother aerodynamics, improved interior ergonomics, and enhanced safety features.
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA.
Production Years:
1996-2003
