🏷️ Basic Information

Make:

Chrysler / Plymouth

Model:

Voyager / Grand Voyager / Town & Country Caravan

Year Start:

1991

Year End:

1995

Generation Name:

Second Generation (RS/ES)

Platform Code:

NS (for 1991-1995 models)

👋 Introduction

Target Audience:

DIY enthusiasts and professional mechanics

Value Proposition:

Cost-effective alternative to dealership service, empowering owners to perform repairs and maintenance.

Content Style:

Detailed illustrations, step-by-step instructions, pictures, and diagrams.

Ease Of Use:

Intuitive electronic format, searchable content (within PDF capabilities).

📋 Manual Details

Specific Models:

Chrysler Voyager, Chrysler Grand Voyager, Plymouth Voyager, Plymouth Grand Voyager, Plymouth Town & Country Caravan

Estimated Pages:

Extensive (typical workshop manuals for this era range from 800-1500+ pages, with this being a comprehensive digital version)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Electronic PDF

📖 Manual Coverage

Engine Systems:

TBI, MPI, ignition, fuel, lubrication, cooling, exhaust, emissions control

Transmission Systems:

Manual transaxle, automatic transaxle (3-speed and 4-speed electronic), power transfer unit

Chassis Systems:

Suspension (front and rear), driveshaft, brakes, steering, wheels, tires

Body And Interior Systems:

Frame, bumpers, body components, heating, air conditioning

Electrical Systems:

Wiring diagrams, lighting, starting, charging, accessories, diagnostic procedures

Emission Control Systems:

Details on EGR, catalytic converters, evaporative emission control systems, and diagnostic procedures for emission-related faults.

Maintenance:

Scheduled maintenance, fluid changes, lubrication, filter replacement

Repair And Rebuild:

Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, steering gear service

Diagnostics And Troubleshooting:

Symptom-based troubleshooting, diagnostic flowcharts, component testing procedures

Component Removal And Installation:

Detailed step-by-step instructions for major and minor component removal and installation

Wiring Diagrams:

Detailed electrical wiring diagrams for all major systems, crucial for diagnosing electrical faults.

Alignment Specifications:

Provides front and rear wheel alignment specifications for proper tire wear and handling.

Depth:

Comprehensive, covering routine maintenance to major component overhaul and diagnostic procedures.

Torque Specifications:

Includes critical torque specifications for engine components, suspension, brakes, and more.

📊 Manual Specifications

Compatibility:

Windows and macOS compatible

Viewing Requirements:

Adobe Acrobat Reader required

Archival Format:

ZIP archive, requires extraction with WinZip or WinRAR

Printability:

All pages are printable

Binding:

Digital (PDF) - not applicable for physical binding

Paper:

Digital (PDF) - not applicable for physical paper type

⚙️ Engine Specifications

Engine 1 Code:

2.5L 4-Cylinder TBI (Throttle Body Injection)

Engine 1 Type:

OHV, Inline 4-Cylinder

Engine 1 Horsepower Est:

~100-109 hp

Engine 1 Torque Est:

~135-140 lb-ft

Engine 1 Fuel System:

Throttle Body Injection (TBI)

Engine 2 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 3 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 4 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 2 Code:

3.8L V6 MPI (Multi-Point Injection)

Engine 2 Type:

OHV, V6

Engine 2 Horsepower Est:

~150-166 hp

Engine 2 Torque Est:

~200-216 lb-ft

Engine 3 Code:

3.3L V6 MPI (Multi-Point Injection)

Engine 3 Type:

OHV, V6

Engine 3 Horsepower Est:

~150-158 hp

Engine 3 Torque Est:

~180-190 lb-ft

Engine 4 Code:

3.0L V6 MPI (Multi-Point Injection)

Engine 4 Type:

SOHC, V6 (Mitsubishi design)

Engine 4 Horsepower Est:

~140-150 hp

Engine 4 Torque Est:

~165-170 lb-ft

🔧 Transmission

Trans 1 Type:

5-Speed Manual Transaxle

Trans 2 Type:

3-Speed Automatic Transaxle (A604/41TE based)

Trans 3 Type:

4-Speed Electronic Automatic Transaxle (A606/42LE based)

Shift Control:

Includes details on clutch operation, transmission fluid types, and shift linkage adjustments.

Automatic Features:

Electronic control for optimal shift points and diagnosis for the 4-speed automatic.

📐 Dimensions

Wheelbase Short Wheelbase:

~111.8 inches (Voyager)

Wheelbase Long Wheelbase:

~119.3 inches (Grand Voyager / Town & Country Caravan)

Length Est:

~177.1 inches (Voyager) to ~184.7 inches (Grand Voyager)

Width Est:

~72.1 inches

Height Est:

~68.4 inches

Curb Weight Est:

~3,500 - 4,200 lbs (depending on engine and configuration)

Cargo Volume Behind 3Rd Row Est:

~15.3 cu ft (Voyager) to ~16.0 cu ft (Grand Voyager)

Cargo Volume Max Est:

~100+ cu ft (with rear seats removed)

🛡️ Safety Features

NHTSA Driver Front Impact 1991:

Four stars

NHTSA Passenger Front Impact 1991:

Four stars

ABS:

Available Anti-lock Braking System (ABS) on select models.

Airbags:

Driver-side airbag standard from 1994 onwards; optional/available on earlier models.

Seatbelts:

Three-point seat belts in all seating positions, with manual front seat belt tensioners.

💡 Technology Features

Audio System:

Basic AM/FM radio, cassette player, and optional CD player. Speaker configurations varied by trim level.

Cruise Control:

Available as an option on most models.

Diagnostic Ports:

OBD-I diagnostic connector, common for this era, requiring specific scan tools or breakout boxes for detailed diagnostics.

🔧 Maintenance

Oil Change Interval Gasoline:

Typically every 3,000 miles or 3 months for conventional oil; may extend with synthetic oil (refer to specific manual recommendations).

Transmission Fluid Change Automatic:

Recommended every 30,000-60,000 miles, depending on driving conditions. Fluid type: ATF+4 (or equivalent as specified in manual).

Coolant Change:

Every 24,000-30,000 miles or 24-36 months. Coolant type: Ethylene Glycol based, typically a 50/50 mix with distilled water.

Spark Plug Replacement:

Varies by engine, typically 30,000-60,000 miles. Consult manual for specific plug types and gaps.

Engine Oil Spec:

Refer to manual for specific viscosity grade (e.g., 5W-30, 10W-30) and API classification (e.g., SF, SG).

Power Steering Fluid Spec:

Refer to manual; typically Mopar power steering fluid or an equivalent ATF.

Automatic Transmission Reliability:

Early versions of the A604 transaxle (used in 3-speed automatic) were known for some reliability concerns; the later 4-speed electronic automatic generally offered improved durability. Transmission fluid changes are critical.

Engine Mounts:

Engine mounts can wear out, leading to vibration and harshness.

Head Gaskets:

The 3.3L and 3.8L V6 engines are generally robust, but head gasket issues can occur over time, particularly if maintenance is neglected.

📚 Vehicle History

Chrysler Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984.

Generation Rs Es:

The second generation (RS/ES) introduced a longer wheelbase option (Grand Voyager/Town & Country) and significant styling and mechanical updates.

Manufacturing Locations:

Primarily manufactured in St. Louis, Missouri, USA.

Sales Impact:

These models were highly successful, solidifying Chrysler's dominance in the minivan market.

🏆 Awards & Recognition

Car And Driver 10Best:

Chrysler minivans, including these generations, were frequent recipients of Car and Driver's '10Best' list for their category-defining innovation and practicality.