Chrysler Voyager 1996-2003 All Service Repair Manual

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Tipo: Car

Proveedor:

SKU: 81489

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

Variantes de producto

Descripción

The Chrysler Voyager, produced from 1996 through 2003, is a full-size minivan known for its spacious interior, versatile seating configurations, and comfortable ride, making it a popular choice for families. Built on the NS/GS platform, this vehicle offers a strong towing capacity for its class and was engineered with pioneering front-wheel-drive technology. Available with a 3.3L V6 or a more powerful 3.8L V6 engine, and paired with a 4-speed automatic transmission, the Voyager provides reliable performance for daily commuting and longer journeys. Its design prioritizes practicality and passenger comfort, solidifying its place among competitors like the Ford Windstar and Honda Odyssey. This comprehensive service and repair manual provides detailed information for all aspects of Voyager maintenance and repair for the 1996-2003 model years. It covers essential procedures such as oil changes, filter replacements, coolant flushes, and brake services, along with in-depth guides for engine mechanicals, fuel and ignition systems, transmissions, drivetrains, suspension, steering, braking, and electrical systems. Detailed troubleshooting guides, diagnostic procedures, and extensive wiring diagrams are included to assist owners and technicians in identifying and resolving issues efficiently. The manual's scope extends to body and interior repairs, HVAC systems, and specific technical specifications, ensuring a thorough understanding for effective vehicle upkeep.

🏷️ 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:

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:

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:

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

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

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.