Chrysler Voyager 1996-2005 Workshop Repair Service Manual

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The Chrysler Voyager, part of the RS generation, represents a versatile minivan produced from 1996 to 2005. Built on a platform shared with its Dodge and Plymouth counterparts, this vehicle...

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Art.-Nr: 69226

Stichworte: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Car Chrysler Marine Misc Outboard Engines Voyager

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Beschreibung

The Chrysler Voyager, part of the RS generation, represents a versatile minivan produced from 1996 to 2005. Built on a platform shared with its Dodge and Plymouth counterparts, this vehicle is renowned for its spacious interior, flexible seating arrangements, and comfortable ride, making it an ideal choice for families and individuals requiring ample passenger and cargo capacity. Offering a compelling value proposition, the Voyager was engineered to meet diverse needs, competing in a segment that demanded practicality and reliability. This comprehensive workshop repair and service manual provides in-depth guidance for maintaining and repairing the Chrysler Voyager models from 1996 through 2005. It covers essential areas including routine maintenance, detailed diagnostics and troubleshooting for engine, transmission, chassis, and electrical systems, as well as bodywork and HVAC components. With over 2000 pages of detailed information, including repair procedures, technical specifications, and electrical schematics, this manual is an indispensable resource for owners and professional technicians alike, ensuring the longevity and optimal performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Generation:

RS (Second Generation)

Codes

Platform Code:

NS/GS (based on Dodge Caravan/Plymouth Voyager)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, individuals requiring versatile passenger and cargo space

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Lumina APV/Trans Sport

Key Features

Selling Points:

Spacious interior, flexible seating configurations, comfortable ride, good value proposition

📋 Manual Details

Coverage Areas

Years Covered:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Page Count

Estimated Page Count:

2000+

Manual Type

Type:

Workshop Repair & Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Transmission (Automatic), Drivetrain

Chassis:

Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc/Drum), Wheels & Tires

Electrical:

Charging System, Starting System, Ignition System, Lighting, Instrumentation, Audio System, Power Accessories, Body Control Modules (BCM), Anti-theft System

HVAC:

Air Conditioning, Heating, Ventilation

Body:

Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, Bumpers, Roof Systems

Procedures Included

Maintenance:

Oil Changes, Filter Replacements, Spark Plug Replacement, Coolant Flush, Brake Fluid Flush, Belt Inspections/Replacement, Tire Rotation, Lubrication Points

Diagnostics Troubleshooting:

OBD-II Codes, Engine Performance Issues, Electrical Faults, HVAC Malfunctions, Drivetrain Noises, Brake System Problems

Repair Overhaul:

Engine Rebuilding, Transmission Overhaul, Brake Component Replacement, Suspension Component Replacement, Steering System Repair, Electrical Component Repair/Replacement

Adjustment Calibration:

Wheel Alignment, Parking Brake Adjustment, Door Latch Adjustment

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Tools Required:

OBD-II Scanner, Multimeter, Specialized Jigs & Fixtures (where applicable)

Wiring Diagrams:

Detailed electrical schematics included for all systems

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Resolution:

High resolution, suitable for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Searchability

Text Search:

Likely searchable text (OCR dependent)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EDZ (3.0L SOHC V6)

Displacement 1:

3.0 Liters (182 cu in)

Configuration 1:

V6 (90-degree bank angle)

Valvetrain 1:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Bore X Stroke 1:

3.50 x 3.13 inches (89.0 x 79.6 mm)

Compression Ratio 1:

8.9:1

Horsepower 1:

Approx. 150-158 hp @ 5000-5200 RPM

Torque 1:

Approx. 170-175 lb-ft @ 2800-3000 RPM

Optional Engine

Engine Code 2:

EGA (3.3L SOHC V6)

Displacement 2:

3.3 Liters (201 cu in)

Valvetrain 2:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Horsepower 2:

Approx. 158 hp @ 5000 RPM

Torque 2:

Approx. 190 lb-ft @ 3200 RPM

Engine Code 3:

JTEC (3.8L SOHC V6)

Displacement 3:

3.8 Liters (230 cu in)

Valvetrain 3:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Horsepower 3:

Approx. 166-180 hp @ 4500-5000 RPM

Torque 3:

Approx. 227-230 lb-ft @ 3200-3400 RPM

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 18.0 gallons (68 L)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic

Transmission Model:

41TE (Chrysler's transverse automatic transmission)

Optional

Transmission Type Optional:

N/A (Automatic only for this generation)

Features

Overdrive:

Yes (4th gear)

Torque Converter:

Lock-up torque converter

Fluid Specifications

Fluid Type:

ATF+4 (Automatic Transmission Fluid, Type 9602)

📐 Dimensions

Exterior

Length:

Approx. 189.3 - 192.9 inches (4808 - 4899 mm) depending on year/trim

Width:

Approx. 72.4 inches (1839 mm)

Height:

Approx. 68.5 - 69.4 inches (1740 - 1763 mm)

Wheelbase:

Approx. 112.1 inches (2847 mm)

Interior

Passenger Capacity:

7-8 Passengers

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 38.9 cu ft (1090 L)

Cargo Volume Max:

Approx. 144.2 cu ft (4083 L) with seats removed

Weights

Curb Weight:

Approx. 3,800 - 4,200 lbs (1724 - 1905 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 5,500 - 5,800 lbs (2495 - 2631 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4/5 Stars (for certain years/configurations)

NHTSA Front Impact Passenger:

4/5 Stars (for certain years/configurations)

IIHS Side Impact:

Acceptable (for certain years/configurations)

Active Features

Standard (4-wheel Anti-lock Braking System)

Traction Control:

Optional on some models/trims

Passive Features

Airbags:

Driver and Passenger Frontal Airbags; Optional Side Airbags (later models)

Seat Belts:

3-point seat belts with pretensioners

Child Seat Anchors:

LATCH System (introduced during this generation)

💡 Technology Features

Infotainment

Audio System:

AM/FM Cassette/CD Player (options varied by trim and year)

Speakers:

4 to 8 Speakers depending on trim level

Driver Assistance

Cruise Control:

Standard on most models

Connectivity

Power Outlets:

12V accessory outlets

Other Features

Power Doors:

Optional power sliding rear door, optional power liftgate

Seating Features:

Fold-and-stow second and third-row seating, optional leather upholstery

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (refer to manual for specifics)

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km)

Spark Plug Replacement:

Every 30,000-100,000 miles (48,000-160,000 km) depending on plug type (e.g., platinum/iridium)

Coolant Flush:

Every 30,000-100,000 miles (48,000-160,000 km) or 2-5 years

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (check owner's manual for exact specification and capacity)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or compatible ethylene glycol-based antifreeze

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Common Problem 1:

Head Gasket Leaks (especially on 3.8L engine)

Common Problem 2:

Transmission problems (solenoids, torque converter clutch)

Common Problem 3:

Power sliding door mechanism issues

Common Problem 4:

Oil leaks (valve cover gaskets, oil pan gaskets)

Common Problem 5:

HVAC blower motor resistor failure

Common Problem 6:

Rear brake drum expansion issues

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Corporation (later DaimlerChrysler)

Model Evolution

Previous Generation:

Chrysler Voyager (1984-1995) - Original minivan platform

Next Generation:

Chrysler Pacifica (2004-2008) - Successor, though with a different market positioning

Production

Assembly Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

Production Span:

1996-2005

Platform Sharing:

Shares platform and many components with Dodge Caravan and Plymouth Voyager of the same era.

🏆 Awards & Recognition

Recognitions

Car And Driver Ranking:

Frequently appeared on Car and Driver's '10Best' list in earlier generations, though competitive landscape intensified.

Consumer Reports Ratings:

Mixed to average ratings for reliability across its lifespan, with specific model years and components showing varying performance.

Certifications

Emissions Standards:

Meets US Federal Emissions Standards for the respective model years.