Chrysler Voyager 1996-2005 Service Repair Workshop Manual

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

17 people are viewing this right now

Tipo: Car

Proveedor:

SKU: 69821

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

Variantes de producto

Descripción

This Service Repair Workshop Manual provides comprehensive information for the Chrysler Voyager, covering production years from 1996 through 2005. The Voyager, a full-size minivan known for its practicality, spaciousness, and family-oriented design, offers flexible seating configurations and sliding rear doors, making it a versatile choice for transport. Throughout its NS/GS generation, Chrysler's commitment to accessible pricing and a strong market presence positioned the Voyager as a key competitor against rivals like the Honda Odyssey and Toyota Sienna. Available with a range of engine options, from a 2.4L inline-4 to various V6 configurations up to 3.8L, and typically equipped with a 4-speed automatic transaxle, the Voyager was engineered for everyday family use. This manual serves as an essential resource for owners, mechanics, and technicians, detailing every aspect of the Chrysler Voyager's maintenance and repair. It covers all major systems, including engine mechanicals, transmission and drivetrain, brakes, steering and suspension, and the electrical system, providing in-depth guidance for diagnostics, troubleshooting, and repair procedures. Within its extensive pages, you will find information on scheduled maintenance, fluid specifications, common known issues, and technical data crucial for keeping the vehicle in optimal condition. The manual's detailed explanations, step-by-step instructions, and high-resolution diagrams are designed to facilitate efficient and accurate servicing.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Generation:

NS/GS (Third Generation)

Production Years Covered By Manual:

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

Codes

Chassis Code:

NS (early), GS (facelift)

👋 Introduction

Market Position

Vehicle Type:

Minivan

Segment:

Full-size Minivan

Competitive Analysis

Key Competitors 1996-2005:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Lumina APV/Silhouette, Mercury Villager.

Key Features

Design Philosophy:

Practicality, spaciousness, family-oriented transport.

Distinctive Attributes:

Sliding rear doors, flexible seating configurations, Stow 'n Go (later generations), accessible pricing.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

1500+

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, assembly, disassembly, timing, lubrication, cooling, fuel delivery (carburetor/injection), ignition, exhaust, emissions control.

Transmission And Drivetrain:

Automatic Transmission (A604, 41TE, 42LE), manual transmission (if applicable), transaxle, differential, CV joints, driveshafts.

Brakes:

Hydraulic system, ABS, front and rear disc/drum brake components, parking brake, hydraulic fluid specifications.

Steering And Suspension:

Power steering system, steering column, rack and pinion, suspension components (struts, shocks, control arms, ball joints, bushings), wheel alignment specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), instrument cluster, wiring diagrams, fuses, relays, body control module (BCM).

HVAC:

Heating, ventilation, air conditioning (A/C) system operation, refrigerant R134a, components (compressor, condenser, evaporator), climate control systems.

Body And Chassis:

Body construction, panels, doors, glass, interior trim, exterior trim, bumpers, frame, rust prevention, sound deadening.

Interior:

Seats, seat belts, airbags, dashboard, center console, trim panels, door panels, carpeting, headliner.

Procedures Included

Scheduled Maintenance:

Oil change intervals, filter replacements, fluid checks and changes, tire rotation, brake inspection, tune-up procedures.

Troubleshooting:

Diagnostic procedures for common problems, fault codes, symptom-based diagnosis for engine, transmission, electrical, and HVAC systems.

Repair Procedures:

Step-by-step instructions for component removal, installation, rebuilding, and replacement across all major vehicle systems.

Diagnostics:

Detailed diagnostic flowcharts, using scan tools, testing electrical circuits, pressure testing, and mechanical component testing.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from routine maintenance and inspections to complete engine and transmission rebuilds and complex electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for on-the-job use.

Print Quality

Image Resolution:

High-resolution images, diagrams, and schematics.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

2.4L Inline-4 (4G64, Mitsubishi Eclipse engine)

Engine Option 2:

3.0L V6 (3.0L 6G72 SOHC, Mitsubishi engine)

Engine Option 3:

3.3L V6 (3.3L EGE SOHC, Chrysler)

Engine Option 4:

3.8L V6 (3.8L EGH SOHC, Chrysler)

Performance

Horsepower Range:

Approx. 130 hp (2.4L) to 180 hp (3.8L)

Torque Range:

Approx. 155 lb-ft (2.4L) to 235 lb-ft (3.8L)

Fuel System

Fuel Injection Type:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Required Octane:

87 (Octane Rating)

🔧 Transmission

Standard

Standard Transmission Type:

4-speed Automatic Transaxle (e.g., 41TE, 42LE)

Optional

Optional Transmission Type:

5-speed Manual Transaxle (rare, primarily on 2.4L models)

Features

Transmission Control:

Electronic automatic transmission control, TorqueFlite (Chrysler branding for automatic).

📐 Dimensions

Exterior

Length:

Approx. 189-195 inches (depending on year/trim)

Width:

Approx. 72 inches

Height:

Approx. 68-69 inches

Interior

Seating Capacity:

7-8 Passengers

Cargo

Cargo Volume Behind First Row:

Approx. 100-150 cu. ft. (with seats removed/folded)

Weights

Curb Weight:

Approx. 3800-4300 lbs

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

Likely 4-star driver, 5-star passenger (varies by year/test protocol)

IIHS Small Overlap Front Crash Rating:

Not applicable to models tested by IIHS during this period.

Active Features

Active Safety Features Available:

Anti-lock Braking System (ABS) - standard on most models, Traction Control System (TCS) - optional on some V6 models.

Passive Features

Passive Safety Features:

Front airbags, optional side airbags (later years), crumple zones, reinforced safety cage, height-adjustable seat belts.

💡 Technology Features

Infotainment

Infotainment Options Early:

AM/FM radio with cassette, optional CD player, basic climate controls.

Infotainment Options Late:

Optional premium audio systems, in-dash CD/DVD players, rear-seat entertainment screens (late GS models).

Driver Assistance

Driver Assistance Features:

Cruise control, parking assist sensors (optional on later models).

Connectivity

Connectivity Features:

Power outlets, optional rear audio controls.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 6-12 months (depending on oil type and driving conditions, consult manual).

Transmission Fluid Change:

Every 30,000-60,000 miles (ATF+4 recommended for Chrysler transmissions).

Spark Plug Replacement:

Every 60,000-100,000 miles (depending on plug type).

Timing Belt Replacement:

If equipped with Mitsubishi 4G64 engine (interference engine), recommended every 60,000-90,000 miles. V6 engines use a timing chain.

Fluid Specifications

Engine Oil Specification:

API Certified SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature).

Coolant Specification:

Chrysler/Mopar Antifreeze/Coolant (Ethylene Glycol based, 50/50 mix with distilled water).

Brake Fluid Specification:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Power Steering Fluid:

Chrysler/Mopar Power Steering Fluid or equivalent.

Known Issues

Common Issue 1:

Transmission issues (e.g., torque converter shudder, shifting problems) in early models, particularly with the A604 transaxle. 41TE/42LE generally more robust.

Common Issue 2:

Cracked dashboard common due to sun exposure.

Common Issue 3:

Power window motor failures, door lock actuator issues.

Common Issue 4:

Erosion of intake manifold gaskets (plastic manifold).

Common Issue 5:

Water pump leaks and thermostat housing issues.

📚 Vehicle History

Brand Heritage

Brand Focus:

Chrysler's established presence in the minivan market following the original Dodge Caravan/Plymouth Voyager success.

Model Evolution

Generation Name:

NS/GS

Major Redesign Year:

1996 (NS generation), 2001 (GS facelift and platform update)

Production

Manufacturing Location:

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

Sales Performance:

Strong sales in the minivan segment during its production run, a key player for Chrysler.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Chrysler minivans (including Voyager) were frequently recognized on Car and Driver's 10Best list in the minivan category during this era.

Ratings

Consumer Reports Reliability:

Varied by model year and engine, with some years showing average or below-average reliability, especially concerning transmission and electrical components. Detailed analysis requires specific year reports.