🏷️ Basic Information

Make:

Plymouth

Model:

Voyager

Years Covered:

1996-2005

Platform:

Chrysler NS (Next Generation Minivan) platform

👋 Introduction

Segment:

Mid-size minivan segment, known for practicality, passenger capacity, and family-oriented features.

Competitors:

Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture/Venture Warner.

Features:

Flexible seating configurations, optional Stow 'n Go seating (later models), front-wheel drive, available all-wheel drive, and a wide range of engine options for its time.

Target Audience:

DIY mechanics, independent repair shops, and owners seeking to perform their own maintenance and repairs to save money.

📋 Manual Details

Geographic Coverage:

North America (primarily)

Trim Levels Covered:

All trim levels including base, SE, LE, LX, EX, and Grand Voyager

Estimated Page Count:

Over 2000 pages (estimated based on typical factory service manuals for this era and scope)

Type:

Factory Service Manual / Workshop Manual

Language:

English

Digital Format:

PDF

Compatibility:

Windows (95, 98, ME, XP, Vista, 7), Linux, MAC OS

Quality:

High-resolution PDF, suitable for printing specific sections or the entire manual.

Binding:

Digital (PDF download)

Paper Type:

Not Applicable (Digital)

📖 Manual Coverage

Engine:

All gasoline engines, including detailed diagnostics, repair, and overhaul procedures for major components like cylinder heads, crankshaft, pistons, and timing systems.

Transmission:

Automatic Transmissions (e.g., 41TE, 42LE, 45RFE). Includes detailed removal, installation, disassembly, assembly, diagnosis, and repair procedures, as well as torque specifications and fluid types.

Drivetrain:

Front-wheel drive (FWD) and all-wheel drive (AWD) systems, including CV joints, drive axles, differentials, and related components.

Suspension:

Front and rear suspension systems, including MacPherson struts, control arms, ball joints, bushings, coil springs, shock absorbers, and steering linkage.

Brakes:

Front and rear disc brakes, anti-lock braking system (ABS) components, hydraulic lines, master cylinder, power booster, and parking brake.

Steering:

Power steering system, steering column, steering gear/rack and pinion, hydraulic pump, and hoses.

Electrical System:

Complete electrical system coverage, including battery, charging system (alternator), starting system (starter motor), lighting, ignition system, fuse box diagrams, relay locations, and wiring harnesses.

Body And Frame:

Body panel repair, door mechanisms, latches, hinges, glass replacement, interior trim, body sealing, and frame straightening procedures.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair, including refrigerant service, compressor, condenser, evaporator, blower motor, and climate controls.

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel filter, fuel pressure regulator, and emissions control systems.

Cooling System:

Radiator, water pump, thermostat, cooling fans, hoses, and coolant specifications.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, and hangers.

Safety Systems:

Airbag system (SRS) diagnosis and replacement procedures, seat belts, and related components. (Note: specific SRS safety precautions will be emphasized).

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and changes, spark plug replacement, belt inspection and replacement.

Diagnostics:

Step-by-step diagnostic flowcharts for common and intermittent problems, using diagnostic trouble codes (DTCs) from the OBD-II system, troubleshooting electrical circuits.

Engine Repair:

Complete engine rebuilds, cylinder head removal and installation, piston and connecting rod service, crankshaft and bearing service, valve train repair, and timing chain/belt replacement.

Transmission Repair:

Internal transmission component repair, valve body service, clutch pack replacement, torque converter service, and transmission fluid service.

Brake System Repair:

Brake pad and rotor replacement, caliper service, brake line replacement, bleeding brake systems, and ABS component replacement.

Suspension And Steering Repair:

Replacement of struts, shocks, ball joints, tie rod ends, bushings, wheel bearings, and power steering pump/rack replacement.

Electrical Troubleshooting:

Wiring diagram interpretation, testing of sensors, actuators, control modules (PCM/ECM), starter, alternator, lighting circuits, and power windows/locks.

HVAC Repair:

Refrigerant system evacuation and recharge, compressor replacement, leak detection, blower motor replacement, and blend door actuator repair.

Body Work:

Dent repair, panel replacement, door alignment, window replacement, weatherstrip installation, and bumper repair/replacement.

Body Control Modules:

Diagnosis and repair of Body Control Modules (BCM) affecting features like interior lights, power locks, and alarm systems.

Depth:

Comprehensive: Covers basic maintenance to full engine and transmission overhauls, including detailed diagnostic procedures and specifications.

Diagnostic Tools:

References for using OBD-II scanners, multimeters, pressure gauges, and specialized diagnostic tools.

⚙️ Engine Specifications

Engine Options:

2.4L (2377cc) I4, 3.0L (2972cc) V6 (Chrysler ECE), 3.3L (3301cc) V6 (Chrysler EGA), 3.8L (3778cc) V6 (Chrysler EGH)

Horsepower Torque Range:

Approx. 150-215 hp and 180-250 lb-ft torque, depending on engine and model year.

Fuel Delivery:

Electronic Fuel Injection (EFI) / Multi-Port Fuel Injection (MPFI)

ECU:

Engine Control Unit (ECU) / Powertrain Control Module (PCM) with OBD-II diagnostics.

🔧 Transmission

Transmission Type:

4-speed automatic transmission (e.g., 41TE, 42LE)

Optional Transmission:

Some models, particularly later ones or those with the 3.8L engine, may have variations like the 45RFE 4-speed automatic.

Transmission Features:

Lock-up torque converter, electronic control for shift points.

📐 Dimensions

Wheelbase:

Approx. 112.2 inches (standard wheelbase) and 119.2 inches (Grand Voyager).

Length:

Varies by wheelbase, typically 177.6 inches (standard) to 184.6 inches (Grand).

Cargo Volume:

Significant cargo volume, exceeding 100 cubic feet in Grand Voyager models with rear seats removed.

Curb Weight Range:

Approximately 3,500 - 4,200 lbs, depending on engine and configuration.

🛡️ Safety Features

NHTSA Ratings:

Varies by year and test, but generally received good to acceptable ratings for its era. Frontal impact ratings should be checked specifically for year of manufacture.

ABS:

Standard or optional Anti-lock Braking System (ABS) on most models.

Airbags:

Driver and passenger front airbags standard on most models. Side airbags became optional or standard on later models.

Seat Belts:

Three-point seat belts for all occupants, integrated into seat designs and pillars.

💡 Technology Features

Audio Options:

AM/FM stereo with cassette and CD player options, speaker configurations varied by trim level.

Cruise Control:

Standard or optional cruise control on most models.

Power Accessories:

Power windows, power door locks, power mirrors available on most trims.

🔧 Maintenance

Oil Change Interval:

Typically 5,000 - 7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).

Transmission Fluid Change:

Recommended every 30,000 - 60,000 miles or as per manual, using the correct fluid type.

Coolant Change:

Initial change at 100,000 miles, then every 50,000 miles. Check manual for specific coolant type (e.g., HOAT).

Engine Oil Type:

SAE 5W-30 or 5W-40 (API certified). Check manual for exact viscosity and specification based on engine and climate.

Transmission Fluid Type:

ATF+4 (for later models), ATF+3 (for earlier models). Crucial to use the correct type for transmission longevity.

Power Steering Fluid:

Chrysler Power Steering Fluid or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Common Problems:

Transmission solenoid issues (especially on 41TE/42LE), oil leaks from valve cover gaskets and oil pan, coolant leaks from intake manifold gaskets (on some V6s), wear on suspension bushings and ball joints, power window regulator failures, occasional HVAC blower motor issues.

Preventative Maintenance:

Regular fluid changes, inspection of belts and hoses, and timely replacement of worn suspension components are key to maintaining reliability.

📚 Vehicle History

Brand Focus:

Plymouth was an entry-level brand in the Chrysler Corporation lineup, often sharing platforms with Dodge and Chrysler vehicles.

Generation:

This generation (NS) represents a significant redesign from the previous one, introducing improved aerodynamics, safety features, and powertrain options.

Production Span:

The Plymouth Voyager nameplate was produced from 1984 until 2001, when the Plymouth brand was discontinued. This manual covers the latter part of its production run.

Manufacturing Location:

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

🏆 Awards & Recognition

Industry Accolades:

The Dodge/Plymouth minivan (often grouped together) was consistently a top seller and frequently appeared on '10 Best' lists from automotive publications during its early production years for its innovation in the minivan segment.