Target Audience:
Families and individuals seeking practical, versatile transportation. The manual targets DIY mechanics, independent repair shops, and owners who prefer to perform their own maintenance and repairs.
Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Toyota Sienna, Honda Odyssey, Mercury Villager.
Vehicle Strengths:
Spacious interior, flexible seating configurations, comfortable ride, strong V6 engine options, available all-wheel drive (AWD).
Manual Value Proposition:
Provides in-depth technical knowledge essential for maintaining and repairing this generation of Chrysler Voyager, saving owners significant costs associated with dealership service.
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system.
Drivetrain:
Transmission (automatic), clutch (if applicable to specific configurations), driveshafts, axles, differentials, AWD systems (if equipped).
Chassis:
Suspension (front and rear), steering system, brake system (hydraulic and mechanical components), wheel alignment.
Electrical:
Wiring diagrams, battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules, engine control modules (ECM/PCM).
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, body seals, glass replacement.
Maintenance:
Routine inspections, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, spark plug replacement, belt and hose inspection/replacement.
Repair:
Component removal and installation, rebuild procedures for major assemblies (engine, transmission), diagnostics and troubleshooting for all systems.
Diagnostics:
On-board diagnostics (OBD-II) troubleshooting, diagnostic trouble codes (DTCs), symptom-based diagnostics, component testing procedures.
Depth:
Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls. Includes detailed diagnostic flowcharts and specifications.
Engine 1:
3.0L V6 (Mitsubishi 6G72 SOHC)
Engine 1 Power:
Approx. 150 hp @ 5000 rpm
Engine 1 Torque:
Approx. 180 lb-ft @ 3000 rpm
Engine 2:
3.3L V6 (Chrysler EBB OHV)
Engine 2 Power:
Approx. 158 hp @ 4500 rpm
Engine 2 Torque:
Approx. 195 lb-ft @ 3200 rpm
Engine 3:
3.8L V6 (Chrysler EGG OHV)
Engine 3 Power:
Approx. 166 hp @ 4400 rpm
Engine 3 Torque:
Approx. 227 lb-ft @ 3200 rpm
Injection Type:
Multi-port Fuel Injection (MPI) for all V6 engines.
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Wheelbase:
Approx. 112.3 inches (2852 mm)
Length:
Approx. 189.4 inches (4811 mm)
Width:
Approx. 74.0 inches (1880 mm)
Height:
Approx. 68.7 inches (1745 mm)
Cargo Volume Behind 1St Row:
Approx. 140.5 cu ft (4000 L)
Cargo Volume Behind 2Nd Row:
Approx. 83.5 cu ft (2364 L)
Curb Weight Min:
Approx. 3700 lbs (1678 kg)
Curb Weight Max:
Approx. 4200 lbs (1905 kg) for AWD models
NHTSA Front Impact Driver:
4 Stars (for certain model years/configurations)
NHTSA Front Impact Passenger:
4 Stars (for certain model years/configurations)
IIHS Side Impact:
Acceptable (varies by year and equipment)
ABS:
Standard on most models, optional on some early trims.
Traction Control:
Optional on select models, particularly AWD variants.
Airbags:
Driver and front passenger airbags standard. Optional side airbags became available on later models.
Seat Belts:
Three-point belts for all seating positions, with front pretensioners.
Oil Change Interval:
Every 3,000 to 7,500 miles (5,000 to 12,000 km) depending on oil type and driving conditions. Consult manual for specific recommendations.
Transmission Fluid Change Interval:
Every 30,000 to 60,000 miles (50,000 to 100,000 km) for the automatic transmission. ATF+3 fluid is critical.
Spark Plug Replacement Interval:
Every 30,000 to 100,000 miles (50,000 to 160,000 km) depending on spark plug type (conventional, platinum, iridium).
Engine Oil Viscosity:
SAE 5W-30 is common for most V6 engines, consult manual for specific viscosity based on ambient temperature.
Coolant Type:
Chrysler/Mopar Antifreeze/Coolant (Ethylene Glycol based, OAT or HOAT).
Engine Issues:
Head gasket leaks (especially 3.3L/3.8L), intake manifold gasket leaks, oil leaks, distributor cap/rotor wear, occasional oil filter housing leaks.
Transmission Issues:
Input clutch drum failure (common in 41TE/42LE transmissions), torque converter shudder, solenoid issues, occasional failure of the power transfer unit (PTU) in AWD models.
Electrical Issues:
Instrument cluster failure (often due to faulty capacitors), power window/lock failures, faulty blend door actuators in HVAC, ABS sensor failures, PCM/ECM failures.
Suspension Chassis Issues:
Wear in ball joints and tie rod ends, sagging rear springs, front strut/shock absorber failure, exhaust system rust and leaks.
Parent Company:
Chrysler Corporation (later DaimlerChrysler, then Fiat Chrysler Automobiles).
Generation Period:
1996-2003. This generation introduced a significant redesign with improved aerodynamics, a more modern interior, and updated powertrains.
Facelifts:
Minor updates and trim changes occurred throughout the production run, but no major mid-cycle refreshes were extensive.
Manufacturing Locations:
Primarily Windsor, Ontario, Canada; St. Louis, Missouri, USA; and Saltillo, Mexico.
Sales Volume:
The Chrysler Voyager and its Dodge/Plymouth siblings were consistently among the best-selling minivans in North America during this period.
Car And Driver 10Best:
While the Voyager nameplate itself might not have consistently made 10Best lists, the minivan segment it competed in was a focus for these awards, with competitors frequently recognized.
Consumer Reports:
Consumer Reports ratings varied significantly by model year and engine, with some years receiving average or below-average marks for reliability, particularly in transmission and electrical systems.
