Positioning:
The Plymouth Voyager was a highly popular minivan, a segment that Chrysler largely defined. This service manual positions itself as the definitive resource for owners and independent repair shops aiming to maintain and repair these vehicles to factory standards.
Competition:
Competed directly with the Ford Windstar, Chevrolet Venture, Pontiac Montana, and Honda Odyssey. The factory service manual offers an advantage over generic aftermarket guides due to its specific and detailed factory-level information.
Value Proposition:
Provides dealer-level diagnostic and repair information, empowering DIY enthusiasts and independent mechanics with the knowledge to service the entire vehicle, saving on dealership labor costs.
Powertrain:
Engine, transmission, drivetrain, exhaust system
Chassis:
Suspension, steering, brakes, wheels, tires
Electrical:
Wiring diagrams, lighting, charging system, ignition system, starter, instruments, accessories, body electronics, power windows, power locks, HVAC controls
Body:
Body panels, doors, windows, seats, interior trim, exterior trim, HVAC system, climate control
Maintenance:
Scheduled maintenance, oil changes, fluid checks and changes, filter replacements, lubrication, tune-ups
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair, body panel repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit testing
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical schematics and diagnostic procedures
Engine 1:
2.4L DOHC 16-Valve 4-Cylinder (ID: EDZ - Turbocharged in some markets/variants, but typically naturally aspirated for Voyager)
Engine 2:
3.0L SOHC 12-Valve V6 (Mitsubishi 6G72)
Engine 3:
3.3L OHV 12-Valve V6 (Chrysler EFA)
Engine 4:
3.8L OHV 12-Valve V6 (Chrysler EGH)
Horsepower Range:
150 hp to 180 hp (depending on engine)
Torque Range:
180 lb-ft to 230 lb-ft (depending on engine)
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Wheelbase Standard:
111.8 inches
Wheelbase Long Wheelbase:
119.3 inches (Grand Voyager)
Length:
187.1 inches (Standard Wheelbase) / 194.6 inches (Long Wheelbase)
Seating Capacity:
7 Passengers (typically 2-2-3 configuration)
Cargo Volume:
Varies by seating configuration and wheelbase, often exceeding 150 cubic feet with rear seats removed.
Curb Weight Range:
Approx. 3,800 - 4,200 lbs (depending on engine and configuration)
NHTSA Front Driver Side Impact:
Likely 4-star (for 1996-1999 models tested)
NHTSA Front Passenger Side Impact:
Likely 4-star (for 1996-1999 models tested)
IIHS Frontal Offset:
Acceptable (for models tested)
ABS:
Standard on most models, optional on some base trims.
Traction Control:
Optional on V6 models, often linked with ABS.
Airbags:
Driver and front passenger airbags standard.
Seat Belts:
All seating positions equipped with three-point seat belts. Driver and front passenger have pretensioners.
Audio System:
Factory AM/FM stereo with cassette player and CD player option. Speaker configurations varied by trim level.
Rear Entertainment:
Optional rear-seat video monitor and VHS player available on higher trims or as dealer-installed accessories.
Cruise Control:
Standard on most models.
Keyless Entry:
Available on higher trim levels or as an option.
Connectivity Features:
Limited by era; primarily focused on basic vehicle functions and entertainment. No factory Bluetooth or USB connectivity.
Oil Change Interval:
Typically every 7,500 miles or 6 months (check owner's manual for specific engine/oil type recommendations).
Transmission Fluid Change:
Recommended every 30,000-60,000 miles, depending on driving conditions (consult manual).
Coolant Flush:
Typically every 30,000-50,000 miles or 2-3 years.
Engine Oil Type:
SAE 5W-30 or 10W-30 (depending on ambient temperature, refer to manual for specific engine)
Transmission Fluid Type:
ATF+4 (Chrysler Mopar)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (typically pink or orange)
Common Problems:
Transmission failure (especially early 4-speed automatics), EGR valve clogging, power window motor failures, coolant leaks from intake manifold (V6 engines), noisy power steering pumps, alternator failures.
Preventative Maintenance:
Regularly inspect and change transmission fluid and filter, clean throttle body and EGR valve, check for coolant leaks, and listen for unusual noises.
Plymouth Legacy:
Plymouth was a brand of Chrysler Corporation known for offering value-oriented vehicles. The Voyager was its flagship minivan, a segment that transformed the automotive landscape.
Generation Ns:
The 1996-2000 models represent the third generation of the Dodge Caravan/Plymouth Voyager. This generation introduced significant styling updates, improved safety features, and more refined powertrains compared to its predecessors.
Manufacturing Locations:
Primarily assembled in St. Louis, Missouri, and Windsor, Ontario, Canada.
