🏷️ Basic Information

Make:

Chrysler

Model:

Voyager

Year:

1996

Body Style:

Minivan

Platform Code:

NS (Second Generation)

👋 Introduction

Positioning:

The Chrysler Voyager (and its Dodge Caravan and Plymouth Voyager siblings) was a segment-defining minivan, offering practicality and family-friendly features. This era represented a mature design in the minivan market.

Competitors:

Dominated the North American minivan segment against competitors like the Ford Windstar, Honda Odyssey (first generation), and Chevrolet Lumina APV/Venture.

Family Focus:

Designed for maximum passenger and cargo capacity, sliding doors, flexible seating arrangements.

Powertrain Options:

Offered robust V6 engines known for their torque and towing capability, suitable for family hauling.

Utility:

Essential for owners and independent repair shops to perform accurate diagnostics, maintenance, and repairs, saving on dealership costs.

📋 Manual Details

Primary Coverage:

Complete factory service and repair procedures for the 1996 Chrysler Voyager.

Trim Levels Covered:

All trim levels (e.g., SE, LE, LX, ES - specific to regional markets).

Estimated Page Count:

1500-2000+

Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Print (original factory publication - may be scanned/reproduced digitally).

📖 Manual Coverage

Powertrain:

Engine, fuel system, exhaust system, transmission (automatic and possibly manual), drivetrain, cooling system, lubrication system.

Chassis:

Suspension (front and rear), steering system, braking system (including ABS), wheels and tires.

Electrical:

Wiring diagrams, lighting, power distribution, ignition system, starting system, charging system, battery, instrumentation, body control modules, comfort and convenience systems.

Body:

Exterior body panels, interior trim, doors, windows, glass, seats, roof systems, bumpers.

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair.

Safety Features:

Airbag system (SRS) diagnosis and repair, seat belts.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes, belt inspections and replacement, spark plug service.

Diagnostics Troubleshooting:

Step-by-step diagnostic charts, symptom analysis, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing.

Repair Rebuild:

Detailed instructions for disassembly, inspection, repair, and reassembly of all major components and systems.

Specifications Tolerances:

Precise measurements, torque specifications, alignment angles, wear limits.

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, electrical system troubleshooting, and body repair.

📊 Manual Specifications

Digital Format Description:

If offered digitally, typically PDF format. High resolution scans are preferred for clarity. Searchable text is a significant advantage.

Print Quality Description:

Original factory manuals are high quality. Reproductions should aim for clear print, legible diagrams, and durable paper.

Binding Type Description:

Originals are typically perfect bound or spiral bound. Reproductions may vary.

Paper Type Description:

Originals use durable, often slightly coated paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Code Common:

3.0L V6 (Mitsubishi 6G72 SOHC)

Engine Displacement 3.0:

2972 cc (181.4 ci)

Engine Bore Stroke 3.0:

91.1 mm x 76.0 mm

Engine Compression Ratio 3.0:

8.9:1

Engine Horsepower 3.0:

140-141 hp @ 4800-4900 rpm

Engine Torque 3.0:

170-174 lb-ft @ 3600-3700 rpm

Engine Code Common:

3.3L V6 (Chrysler EDB SOHC)

Engine Displacement 3.3:

3301 cc (201.5 ci)

Engine Bore Stroke 3.3:

93.0 mm x 81.0 mm

Engine Compression Ratio 3.3:

8.9:1

Engine Horsepower 3.3:

156 hp @ 4800 rpm

Engine Torque 3.3:

190 lb-ft @ 3600 rpm

Engine Code Common:

3.8L V6 (Chrysler EGA SOHC)

Engine Displacement 3.8:

3778 cc (230.5 ci)

Engine Bore Stroke 3.8:

96.0 mm x 86.0 mm

Engine Compression Ratio 3.8:

8.9:1

Engine Horsepower 3.8:

166 hp @ 4500 rpm

Engine Torque 3.8:

215 lb-ft @ 3000 rpm

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher octane for improved performance possible)

🔧 Transmission

Type Standard:

4-speed Automatic (A604/41TE - Ultradrive/AutoStick)

Type Optional:

No manual transmission typically offered on Voyager models for this year in North America.

Transmission Control:

Electronic control with adaptive shift logic.

Transmission Fluid Type:

ATF+4 (or equivalent specification from manual - check for Mopar ATF+3, which was standard and later updated to ATF+4 by Chrysler).

📐 Dimensions

Wheelbase:

113.0 inches (2870 mm)

Length:

177.1 - 183.1 inches (4498 - 4651 mm) depending on configuration

Width:

72.1 inches (1831 mm)

Height:

66.6 inches (1692 mm)

Curb Weight Range:

Approx. 3700 - 4100 lbs (1680 - 1860 kg) depending on engine and configuration.

Cargo Volume Behind 3Rd Row:

Varies by configuration, typically around 30-40 cubic feet.

Cargo Volume Max:

Over 140 cubic feet with rear seats removed.

🛡️ Safety Features

NHTSA Front Driver Impact:

Likely 4-star rating (check specific year/testing data).

NHTSA Front Passenger Impact:

Likely 4-star rating (check specific year/testing data).

IIHS Crash Test Performance:

Check specific IIHS reports for this generation. Minivans of this era often had mixed results.

ABS:

Anti-lock Braking System (ABS) typically optional or standard on higher trims.

Traction Control:

Traction control system (TCS) became available or standard on some models in this period.

Airbags:

Driver and passenger front airbags (SRS).

Seat Belts:

Three-point seat belts for all occupants, with front seat belt pretensioners.

Child Safety:

Rear door child safety locks, LATCH system may not be standard (check specifics).

💡 Technology Features

Audio System:

Factory AM/FM cassette or CD player. Speaker configurations varied by trim level.

Climate Control:

Manual or optional automatic climate control systems.

Cruise Control:

Standard or optional cruise control.

Keyless Entry:

Optional keyless entry system.

Wiring Diagrams:

Comprehensive wiring diagrams are a key feature of the manual, essential for diagnosing electrical faults.

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 3-6 months, depending on driving conditions (check manual for severe vs. normal service).

Engine Coolant Change:

Initial fill may last longer, but typically recommended every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-3 years.

Transmission Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-4 years, depending on use (heavy use requires more frequent service).

Spark Plug Replacement:

Around 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (platinum/iridium offer longer life).

Engine Oil Type:

SAE 5W-30 or 5W-40, API Service SG or SH (check manual for specific recommendations).

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) for 3.0L, 5.0 quarts (4.7 liters) for 3.3L/3.8L (with filter change).

Coolant Type:

Mopar Antifreeze/Coolant (50/50 mix with distilled water) or equivalent HOAT coolant.

Power Steering Fluid:

Mopar Power Steering Fluid or Dexron III ATF.

Transmission Issues:

Early 41TE transmissions could be prone to solenoid issues, torque converter shudder, or hard shifting if not properly maintained. Fluid and filter changes are critical.

Head Gaskets:

Some V6 engines, particularly the 3.8L EGH, could be susceptible to head gasket failures, often indicated by coolant loss or white smoke from the exhaust.

Power Window Motors:

Window regulators and motors are common wear items, especially on sliding doors.

Climate Control Blend Doors:

Actuator motors for HVAC blend doors can fail, leading to incorrect air temperature or airflow direction.

Suspension Components:

Wear in ball joints, tie rod ends, and bushings can lead to poor handling and steering issues over time.

📚 Vehicle History

Chrysler Legacy:

Chrysler has a long history in automotive manufacturing, particularly known for its innovation in segment creation, like the minivan.

Generation Ns:

The 1996 model is part of the second generation (NS) of the Chrysler minivans, introduced for the 1996 model year. This generation brought significant styling and mechanical updates.

Design Updates:

Key changes for the NS generation included more aerodynamic styling, a redesigned interior, and improvements to safety and handling.

Production Plants:

Primarily produced in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

Production Years:

The NS generation ran from 1996 to 2000.

🏆 Awards & Recognition

Car And Driver 10Best:

Chrysler minivans were frequent recipients of Car and Driver's '10Best' list in earlier iterations, establishing their market dominance and quality perception.

Consumer Reports Reliability:

Reliability ratings from this era can vary. The manual is crucial for understanding how to maintain these vehicles to mitigate common wear-and-tear issues.