Market Segment:
Mid-size Minivan
Competitors:
Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Honda Odyssey, Toyota Sienna
Key Features Vehicle:
Spacious interior, flexible seating, family-oriented design, front-wheel drive
Key Features Manual:
Detailed diagrams, clear step-by-step instructions, troubleshooting charts, specification tables
Systems Covered:
Engine, Transmission (Automatic), Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body & Frame, Interior, Exterior, Emissions Control, Maintenance, Troubleshooting, Diagnostics
Page Count:
Approx. 1000+
Manual Type:
Shop Service Repair Manual
Engine Mechanical:
Complete overhaul, component replacement, timing, cooling system, lubrication system
Engine Performance:
Fuel delivery, ignition system, emissions control, diagnosis and testing
Automatic Transmission:
Service and overhaul of the 41TE/42LE transmission, hydraulic controls, torque converter
Drivetrain:
Front-wheel drive system, CV joints, drive axles, differential
Suspension:
Front and rear suspension systems, struts, springs, bushings, alignment specifications
Steering:
Power steering system, steering gear, steering column, tie rods
Brakes:
Front and rear brake systems (disc/drum), ABS diagnosis and repair, hydraulic system
Electrical System:
Battery, charging system, starting system, lighting, instrumentation, power accessories, wiring diagrams
HVAC:
Air conditioning system, heating system, climate control, component replacement
Body And Frame:
Body panel repair, structural components, door mechanisms, glass replacement, underbody coatings
Interior:
Seating systems, dashboard, trim panels, seatbelt service, airbag system information
Exterior:
Bumpers, grille, mirrors, trim, seals
Emissions Control:
EGR system, catalytic converter, evaporative emission control system, diagnosis
Maintenance Procedures:
Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, belt inspection/replacement
Diagnostic Procedures:
Systematic troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, component testing
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment
Rebuild Procedures:
Detailed instructions for major component overhauls (e.g., engine, transmission)
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems
Depth Of Information:
Comprehensive, covering routine maintenance to complete engine and transmission overhauls, including electrical system diagnostics and body repair
Airbags:
Driver and passenger front airbags
Seatbelts:
Front: 3-point height-adjustable, Rear: 3-point lap and shoulder belts
Child Safety:
Rear door child safety locks
NHTSA Rollover Rating 2003:
3 stars (for models equipped with 4WD, not applicable to 2WD Voyager)
ABS:
Anti-lock Braking System (ABS) available
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months, whichever comes first (under normal driving conditions).
Tire Rotation Interval:
Every 6,000 miles (9,600 km) or 6 months
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 30,000 miles (48,000 km) (platinum-tipped plugs recommended)
Engine Oil Type:
SAE 5W-30
Engine Oil Capacity:
4.0 quarts (3.8 liters) with filter
Coolant Type:
Mopar Antifreeze/Coolant (50/50 mix with distilled water)
Coolant Capacity:
Approx. 10.5 quarts (9.9 liters)
Power Steering Fluid Type:
ATF+4 or Mopar Power Steering Fluid
Common Issues Engine:
Intake manifold gasket leaks, oil filter housing leaks, intermittent stalling, oxygen sensor failures.
Common Issues Transmission:
Torque converter shudder, solenoid failures, transmission fluid leaks.
Common Issues Suspension:
Worn ball joints, tie rod ends, and control arm bushings; noisy struts.
Common Issues Electrical:
Faulty power window motors, power door lock actuators, intermittent dashboard warning lights.
Brand Focus:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984.
Generation:
Second Generation (NS) 1996-2000
Design Changes From Previous Gen:
All-new exterior and interior styling, improved aerodynamics, increased interior space, available all-wheel drive (though not standard on Voyager)
Manufacturing Plant:
Windsor Assembly Plant, Windsor, Ontario, Canada
Production Years For Gen:
1996, 1997, 1998, 1999, 2000
