Chrysler Voyager 1996 Full Service Repair Manual

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Stichworte: 1996 Car Chrysler Marine Misc Outboard Engines Voyager

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Beschreibung

The 1996 Chrysler Voyager is a versatile minivan, a continuation of Chrysler's pioneering legacy in the minivan segment. Designed for families and fleet operators, this second-generation model (NS chassis) offers a spacious and adaptable interior, a comfortable ride, and a reputation for widely available parts. It was offered with a choice of three capable V6 engines: the 3.0L Mitsubishi, the 3.3L Chrysler EDB, and the more powerful 3.8L Chrysler EGD, all paired with a smooth automatic transmission, with an all-wheel-drive option available. Its practical design and focus on passenger comfort made it a strong contender in the competitive North American market of its era. This comprehensive Full Service and Repair Manual provides in-depth guidance for the 1996 Chrysler Voyager, covering all essential systems. The manual details maintenance procedures, diagnostic troubleshooting, and repair instructions for the engine, transmission, brakes, suspension, and electrical systems. It includes technical specifications, wiring diagrams, and information on body and chassis repairs, as well as fluid and component recommendations. With over 1500 pages of information in English, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair the vehicle effectively, ensuring its optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Minivan / MPV

Target Audience:

Families, fleet operators, DIY mechanics

Competitive Analysis

Key Competitors:

Dodge Grand Caravan, Ford Windstar, Chevrolet Venture/Lumina APV, Toyota Previa, Honda Odyssey

Key Features

Vehicle Strengths:

Spacious interior, versatile seating, comfortable ride, widely available parts

Manual Value Proposition:

Provides essential, detailed information for maintaining and repairing the Chrysler Voyager, saving owners significant costs on professional servicing.

📋 Manual Details

Coverage Areas

Markets Covered:

North America (USDM, C/V variants)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Full Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

3.0L V6 (Mitsubishi 6G72), 3.3L V6 (Chrysler EDB), 3.8L V6 (Chrysler EGD)

Transmission:

3-speed Automatic (A604/40TE/41TE - FWD), 4-speed Automatic (42LE - AWD)

Brakes:

Front Disc, Rear Drum (with ABS option)

Suspension:

Front MacPherson Strut, Rear Torsion Beam Axle

Electrical System:

Full Wiring Diagrams, Charging System, Starting System, Ignition System, Lighting, Instrumentation, HVAC Controls, Power Accessories

Body And Chassis:

Body Panel Repair, Doors, Windows, Seats, Interior Trim, Frame Alignment

Fuel System:

Fuel Pump, Injectors, Lines, Evaporative Emissions Control

Cooling System:

Radiator, Water Pump, Thermostat, Fan Operation

Exhaust System:

Manifolds, Catalytic Converter, Mufflers, Pipes

Steering:

Power Steering System, Steering Column, Linkages

Climate Control:

HVAC System, A/C Compressor, Heater Core, Blower Motor

Procedures Included

Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Tune-ups, Brake Pad Replacement, Belt Replacement

Diagnostics:

Component Testing, Fault Code Retrieval (OBD-II), Troubleshooting Guides

Repair:

Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical Component Repair

Rebuilding:

Engine Mechanical Components, Transmission Internal Components

Refurbishing:

Interior Components, Exterior Bodywork

Restoration:

General body and mechanical restoration guidance

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (OCR processed)

Print Quality

Resolution:

High-resolution scans for clear diagrams and text

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

3.0L (182 cu. in.)

Engine 1 Configuration:

SOHC V6 (Mitsubishi 6G72)

Engine 1 Horsepower:

141 hp @ 5000 rpm

Engine 1 Torque:

167 lb-ft @ 3750 rpm

Engine 2 Displacement:

3.3L (201 cu. in.)

Engine 2 Configuration:

OHV V6 (Chrysler EDB)

Engine 2 Horsepower:

158 hp @ 4850 rpm

Engine 2 Torque:

190 lb-ft @ 3400 rpm

Engine 3 Displacement:

3.8L (230 cu. in.)

Engine 3 Configuration:

OHV V6 (Chrysler EGD)

Engine 3 Horsepower:

166 hp @ 4500 rpm

Engine 3 Torque:

227 lb-ft @ 3000 rpm

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Standard Transmission:

4-speed Automatic (FWD)

Optional

Optional Transmission:

4-speed Automatic AWD (for 3.8L engine)

Features

Transmission Control:

Electronic (with torque converter lock-up)

Transmission Fluid Type:

ATF+4 (or equivalent) - Verify specific application in manual

📐 Dimensions

Exterior

Wheelbase:

119.3 inches

Length:

191.7 inches

Width:

76.4 inches

Height:

68.2 inches

Weights

Curb Weight Est:

3,700 - 4,100 lbs (depending on engine and configuration)

Gross Vehicle Weight Rating Est:

5,500 - 5,800 lbs

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

Likely 4-star (based on era and typical ratings for this vehicle class)

NHTSA Passenger Front Impact:

Likely 4-star (based on era and typical ratings for this vehicle class)

Active Features

Optional Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Seat Belts:

Three-point seat belts in all outboard seating positions, lap belts in center positions

💡 Technology Features

Infotainment

Audio System:

AM/FM Cassette, Optional CD Player, Up to 6 Speakers

Driver Assistance

Cruise Control:

Standard on most trims

Connectivity

Interior Features:

Optional rear-seat entertainment (video cassette player), overhead console with trip computer

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months, whichever comes first (or 7,500 miles with synthetic oil - check manual for specifics)

Transmission Fluid Change Interval:

Every 30,000 - 60,000 miles (depending on driving conditions - consult manual)

Engine Coolant Flush Interval:

Every 30,000 miles or 24 months

Spark Plug Replacement Interval:

100,000 miles (with platinum-tipped plugs)

Fluid Specifications

Engine Oil Type And Viscosity:

API SG/SH, SAE 5W-30 or 10W-30 (refer to manual for specific engine and temperature recommendations)

Engine Coolant Type:

Mopar Antifreeze/Coolant (5/150 Formula) or equivalent HOAT

Power Steering Fluid:

ATF+4 (or specified Mopar fluid)

Brake Fluid:

DOT 3

Known Issues

Common Problems:

Transmission solenoid failures (especially the 42LE), EGR valve issues, power window regulator failures, occasional head gasket leaks on the 3.3L/3.8L engines, fuel pump failure.

Preventative Measures:

Regular transmission fluid and filter changes are crucial for longevity. Keep cooling system in good condition to prevent overheating.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler is credited with inventing the modern minivan segment with the Dodge Caravan and Plymouth Voyager in 1984. The 1996 model represents the second generation of Chrysler's minivan platform.

Model Evolution

Generation:

Second Generation (1996-2000)

Design Changes From Previous:

Smoother styling, improved aerodynamics, larger interior volume, available all-wheel drive (AWD).

Production

Manufacturing Plant:

Windsor, Ontario, Canada

🏆 Awards & Recognition

Recognitions

Automotive Journal Awards:

Chrysler minivans consistently received accolades for their practicality and innovation throughout the 1990s, though specific awards for the 1996 model year vary by publication.