Model Generations Covered:
Second Generation (RS)
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Key Competitors:
Dodge Grand Caravan/Caravan, Ford Windstar, Honda Odyssey, Toyota Sienna
Vehicle Appeal:
Spacious interior, flexible seating, family-oriented, practical cargo hauling
Manual Value Proposition:
Comprehensive guide for DIY mechanics and professional technicians to maintain and repair the Plymouth Voyager, ensuring longevity and optimal performance.
Powertrain:
Engine (3.0L V6, 3.3L V6, 3.8L V6), Transmission (3-speed Automatic, 4-speed Automatic)
Chassis:
Suspension, Steering, Brakes, Wheels, Tires
Body And Frame:
Body Panels, Doors, Seats, Interior Trim, Exterior Trim, Glass, HVAC System
Electrical:
Ignition System, Charging System, Starting System, Lighting, Instrumentation, Audio System, Power Accessories, Body Control Modules, Powertrain Control Modules (PCM)
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication
Diagnostics:
Troubleshooting charts, diagnostic trouble codes (DTCs), circuit diagrams, component testing
Repair And Overhaul:
Engine disassembly and assembly, transmission overhaul, brake system repair, suspension component replacement, electrical system diagnostics and repair
Installation And Removal:
Component removal and installation procedures for all major systems
Bodywork:
Body panel alignment, rust repair, collision repair guidance, door mechanisms, window regulators
HVAC:
Air conditioning system diagnosis and repair, heater core replacement, blower motor service, climate control system operation
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed schematics and specifications
Diagrams And Illustrations:
Detailed exploded diagrams, wiring schematics, diagnostic flowcharts, and step-by-step photographic guides
Digital Quality:
High-resolution PDF, searchable text
Printability:
Fully printable, allows for easy referencing in a workshop environment
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download, but designed for print clarity)
Operating Systems:
Windows, Mac OS, Linux
Software Requirement:
Adobe Acrobat Reader or compatible PDF viewer
Engine 1:
3.0L V6 (Mitsubishi 6G72 SOHC)
Engine 2:
3.3L V6 (Chrysler E-G RBX OHV)
Engine 3:
3.8L V6 (Chrysler E-G L32 OHV)
Horsepower Range:
Approximately 150 HP to 180 HP (depending on engine and year)
Torque Range:
Approximately 180 lb-ft to 235 lb-ft (depending on engine and year)
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Timing Belt Replacement:
Required for 3.0L Mitsubishi engine (typically every 60,000 miles or 5 years)
Engine Oil Capacity 3.3L:
4.5 US Quarts (4.3 Liters) with filter change
Spark Plug Type 3.8L:
Champion RE10PYPB4 or equivalent
Engine Oil Capacity 3.8L:
4.5 US Quarts (4.3 Liters) with filter change
Transmission 1:
4-speed Automatic (A604/41TE/42LE)
Transmission 2:
3-speed Automatic (A727/30RH) - Less common in later years
Transmission Control:
Electronic Pressure Control (EPC) in 4-speed automatic transmissions
Transmission Fluid Type:
ATF+4 (Mopar)
Transmission Fluid Capacity 42Le:
7.5 US Quarts (7.1 Liters) with filter change
Length:
Approx. 177.9 - 181.2 inches (depending on configuration)
Width:
Approx. 71.7 - 72.0 inches
Height:
Approx. 68.4 - 69.9 inches
Curb Weight:
Approx. 3,700 - 4,200 lbs (depending on engine and configuration)
Gross Vehicle Weight Rating Gvwr:
Approx. 5,500 - 6,000 lbs
NHTSA Frontal Crash Rating Driver:
4/5 stars (for 1996-1997 models, some variations exist)
NHTSA Frontal Crash Rating Passenger:
4/5 stars (for 1996-1997 models, some variations exist)
ABS:
Standard on most models, optional on early models
Traction Control:
Optional on some models
Airbags:
Driver and passenger front airbags standard
Seat Belts:
All seating positions equipped with three-point seat belts; front seat belt pretensioners
Audio System:
Factory AM/FM stereo with cassette and CD player (optional), AM/FM stereo with single-disc CD (later models)
Entertainment Options:
Optional rear-seat entertainment systems were available on some higher trims.
Cruise Control:
Standard on most models
Keyless Entry:
Optional feature
Power Accessories:
Power windows, power door locks, power mirrors were available/standard depending on trim level
Oil Change Interval:
Every 3,000 to 7,500 miles or 3 to 6 months, depending on oil type and driving conditions (refer to manual for specifics)
Engine Coolant Flush:
Every 30,000 miles or 2-3 years
Transmission Fluid Change Interval:
Every 30,000 to 60,000 miles or 2-4 years, depending on driving conditions and fluid condition (refer to manual)
Engine Oil Spec:
API Certified SAE 5W-30 or 10W-30 (check owner's manual for specific recommendations based on temperature)
Power Steering Fluid:
Mopar Power Steering Fluid or Dexron III ATF
Transmission Slippage:
Common concern with 4-speed automatic transmissions, often related to solenoid issues or low fluid pressure. Requires detailed diagnostic procedures outlined in the manual.
Headliner Sagging:
Fabric on the headliner can detach due to adhesive breakdown over time.
Wiper Motor Failure:
The park function of the wiper motor can fail, causing wipers to stop in an arbitrary position.
Rear Wiper Failure:
The rear wiper motor or linkage can fail.
Wheel Lug Nut Torque:
100 ft-lbs (135 Nm)
Brand History:
Plymouth was an automotive brand of Chrysler Corporation, known for offering value-oriented vehicles. The Voyager was a flagship model for the brand.
Second Generation Launch:
Introduced for the 1996 model year, the second-generation RS platform brought significant styling and engineering updates, including a more aerodynamic design and improved safety features.
Key Updates During Generation:
Introduced the 3.3L and 3.8L V6 engines, improved interior comfort and features, enhanced safety systems, and styling refreshes. The Plymouth brand was discontinued after the 2001 model year, with remaining Voyagers being rebadged as Chrysler Voyagers or Dodge Caravans.
Production Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA