Chrysler Voyager 1996-2003 Workshop Service Manual Repair

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The Chrysler Voyager, a key player in the mid-size minivan segment, was produced from 1996 to 2003. This second-generation model, built on the NS/GS platform, offered a spacious interior, flexible...

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Art.-Nr: 56412

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

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Beschreibung

The Chrysler Voyager, a key player in the mid-size minivan segment, was produced from 1996 to 2003. This second-generation model, built on the NS/GS platform, offered a spacious interior, flexible seating configurations, and a comfortable ride, making it a popular choice for families. Available with a range of engines, including 2.4L inline-four and 3.0L or 3.3L V6 options, and an optional all-wheel-drive system, the Voyager provided versatility for various needs. Chrysler’s pioneering legacy in the minivan market is evident in the Voyager's design, which aimed to balance practicality with passenger comfort and convenience, competing with established models from Ford, Toyota, Honda, and Chevrolet. This comprehensive workshop service manual is designed to guide owners, technicians, and mechanics through the maintenance, diagnosis, and repair of the Chrysler Voyager models from 1996 through 2003. It covers all major systems, including detailed procedures for engine mechanicals, transmission overhauls, brake systems, suspension and steering, electrical and electronic components, body and chassis work, and HVAC systems. The manual provides step-by-step repair instructions, routine maintenance schedules, troubleshooting guides for common issues, and essential technical specifications, empowering users to maintain their vehicle's performance and reliability.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Codes

Platform Code:

NS/GS (Second Generation)

👋 Introduction

Market Position

Segment:

Mid-size Minivan

Competitive Analysis

Competitors:

Ford Windstar, Toyota Sienna, Honda Odyssey, Chevrolet Venture/Silhouette/Trans Sport.

Key Features

Vehicle Highlights:

Spacious interior, flexible seating configurations, comfortable ride, availability of all-wheel drive on some models.

Manual Value Proposition

Benefit To Owner:

Empowers owners and independent repair shops with the technical knowledge to perform maintenance, diagnostics, and repairs efficiently and correctly, saving time and money.

📋 Manual Details

Coverage Areas

Years Covered:

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

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Comprehensive engine diagnostics, overhaul procedures, timing belt replacement, cooling system, lubrication system, fuel delivery, emissions control systems.

Transmission Mechanical:

Automatic transmission (e.g., 42LE, 41TE) overhaul, repair, fluid service, torque converter replacement, electronic control unit (ECU) diagnostics.

Brakes:

Hydraulic system, brake fluid service, ABS diagnostics and repair, caliper and rotor replacement, parking brake adjustment.

Suspension Steering:

Front and rear suspension components, struts, shocks, control arms, ball joints, power steering system, steering rack, alignment procedures.

Electrical Electronics:

Wiring diagrams, charging system (alternator, battery), starting system, ignition system, lighting, power windows, power locks, interior electronics, fuse and relay identification, diagnostic trouble codes (DTCs).

Body Chassis:

Body panel repair, door mechanisms, interior trim removal, glass replacement, underbody components, chassis lubrication.

HVAC:

Air conditioning system service, refrigerant handling, heater core replacement, blower motor, climate control system diagnostics.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, DTC interpretation.

Repair Overhaul:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Special Tools:

Identification and usage instructions for specialized tools required for specific repairs.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds; includes detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution scans, searchable text, clear diagrams and illustrations.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.4L DOHC I4 (150 hp @ 5,200 rpm, 175 lb-ft @ 3,800 rpm)

Engine 2:

3.0L SOHC V6 (150-158 hp @ 5,200-5,400 rpm, 180-190 lb-ft @ 3,600-4,000 rpm)

Engine 3:

3.3L SOHC V6 (180 hp @ 5,200 rpm, 210 lb-ft @ 3,600 rpm) - Introduced later in the generation

Performance

Horsepower Range:

150-180 hp

Torque Range:

175-210 lb-ft

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Engine Codes

Common Engine Codes:

EDZ (2.4L I4), EAT (3.0L V6), EHB (3.3L V6)

Cooling System

Coolant Capacity:

Approx. 9.5 quarts (9.0 L)

🔧 Transmission

Standard

Transmission Standard:

4-Speed Automatic

Optional

Transmission Optional:

All-Wheel Drive (AWD) system, typically with the V6 engines.

Features

Transmission Type Code:

42LE (for 3.0L V6), 41TE (for 3.3L V6 and some 2.4L applications)

Fluid Specifications

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid +4), formerly ATF+3. Refer to manual for exact specification for model year.

Fluid Capacity

Transmission Fluid Capacity:

Approx. 6.0 - 7.0 quarts (5.7 - 6.6 L) for a fluid service.

📐 Dimensions

Exterior

Length:

Approx. 189.4 inches (4811 mm)

Width:

Approx. 72.1 inches (1831 mm)

Height:

Approx. 67.6 inches (1717 mm)

Wheelbase

Wheelbase:

Approx. 112.1 inches (2847 mm)

Weights

Curb Weight Range:

Approx. 3,700 - 4,100 lbs (1678 - 1860 kg), varies by engine and drivetrain.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Likely 4-star for driver and front passenger (based on typical ratings for this era/segment).

IIHS Side Impact:

Ratings vary by year, check specific vehicle year for detailed IIHS data.

Active Features

Standard on most models, Antilock Braking System.

Passive Features

Airbags:

Driver and front passenger airbags standard.

Seat Belts:

Front and rear seat belts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio Options:

AM/FM cassette/CD player, optional premium sound systems, rear seat entertainment options on some higher trims.

Climate Control:

Manual HVAC controls, optional automatic climate control systems.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Power Accessories:

Power windows, power door locks, power sliding doors (optional on some models).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 to 7,500 miles (4,800 to 12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specifics).

Transmission Fluid Change:

Recommended every 30,000 to 60,000 miles (48,000 to 96,000 km), or as per severe driving conditions.

Timing Belt Replacement:

Critical for the 2.4L engine (interference engine). Typically every 60,000 to 100,000 miles (96,000 to 160,000 km). V6 engines often use timing chains.

Fluid Specifications

Engine Oil Type:

API Certified SAE 5W-30 or 10W-30 (depending on ambient temperature). Refer to owner's manual for exact viscosity and specification.

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a green or orange color. Mopar 5/100 coolant or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Problems 1:

Transmission solenoid issues (especially in the 42LE), A/C evaporator leaks, rear suspension sag, power window motor failures, potential head gasket issues on some V6 engines.

Common Problems 2:

EGR valve clogging (especially on 3.0L V6), O2 sensor failures, exhaust system corrosion, occasional electrical gremlins (e.g., power door locks).

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. The Voyager is the Chrysler-branded version.

Model Evolution

Generation Description:

This period covers the second generation (NS/GS) of the Chrysler Voyager, characterized by updated styling, improved safety features, and more powerful engine options compared to the first generation.

Production

Manufacturing Plants:

St. Louis Assembly (Missouri, USA) and Windsor Assembly (Ontario, Canada).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Chrysler minivans, including variants of the Voyager/Grand Voyager, were frequently recognized on Car and Driver's '10Best' lists in the early to mid-1990s.

Ratings

Consumer Reports:

Ratings varied across model years, with some years showing better reliability than others, particularly concerning transmission and powertrain components. This manual provides the means to address common issues.