Chrysler Voyager 1999 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Year: 1999 Product Name: Chrysler Voyager 1999 Full Service Repair Manual PDF Download 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Year:

Product Name:

Chrysler Voyager 1999 Full Service Repair Manual PDF Download

👋 Introduction

Market Position

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families and individuals seeking versatile transportation with ample passenger and cargo space.

Competitive Analysis

Key Competitors Era:

Ford Windstar, Chevrolet Venture, Pontiac Montana, Nissan Quest, Honda Odyssey.

Key Features

Design Philosophy:

Practicality, spaciousness, and family-friendly features.

Innovation Points:

Offered front-wheel drive, a more car-like driving experience than earlier vans, and flexible seating configurations.

📋 Manual Details

Coverage Areas

Manual Type:

Full Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed repair procedures for engine assembly, disassembly, rebuilding, and tuning.

Engine Fuel System:

Diagnosis and repair of fuel injection systems, fuel pumps, injectors, and evaporative emission controls.

Engine Cooling System:

Maintenance and repair of radiators, water pumps, thermostats, and cooling fans.

Engine Lubrication System:

Oil pump, oil filter replacement, oil pan removal and installation.

Ignition System:

Spark plugs, ignition coils, distributor (if applicable), and ignition timing.

Emission Control System:

Components like EGR valve, catalytic converter, oxygen sensors, and diagnostic trouble codes (DTCs).

Transmission Automatic:

Overhaul, repair, and diagnostic procedures for automatic transmissions, including torque converter.

Transmission Manual:

If equipped, repair and maintenance of manual gearboxes, clutch assembly.

Drivetrain Axles:

Front-wheel drive axle shafts, CV joints, and differential maintenance.

Suspension System:

Front and rear suspension components, shock absorbers, struts, bushings, and alignment procedures.

Steering System:

Power steering pump, rack and pinion, steering linkage, and alignment.

Brake System:

Front and rear brake calipers, rotors, pads, brake lines, master cylinder, and ABS diagnostics.

Electrical System Wiring:

Complete wiring diagrams, fuse box locations, relay functions, and troubleshooting.

Body And Frame:

Body panel repair, door mechanisms, glass replacement, and frame straightening (if applicable).

HVAC System:

Air conditioning and heating system diagnosis, refrigerant service, blower motor, and climate controls.

Interior Components:

Seat removal, dashboard disassembly, trim panel replacement.

Safety Systems:

Airbag system diagnosis and repair, seat belt mechanisms.

Procedures Included

Preventive Maintenance:

Oil change intervals, filter replacements, fluid checks, tire rotation, and general inspection procedures.

Troubleshooting Diagnostics:

Step-by-step diagnostic guides for common and complex issues across all vehicle systems, including DTC interpretation.

Component Repair Rebuild:

Detailed instructions for the removal, repair, reassembly, and installation of all major and minor vehicle components.

Torque Specifications:

Precise torque values for all critical fasteners and bolts.

Electrical Troubleshooting:

Detailed wiring diagrams and logic trees for pinpointing electrical faults.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Level Of Detail:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds.

Repair Information:

Step-by-step repair procedures with clear instructions and diagrams.

Diagnostic Procedures:

Advanced diagnostic techniques for identifying and resolving complex mechanical and electrical issues.

Schematics Diagrams:

Includes detailed electrical schematics, vacuum diagrams, and exploded views of components.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick information retrieval.

Printability:

Designed for printing specific sections or the entire manual.

Digital Access:

Instant download access.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Text Clarity:

Crisp and readable text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Various, commonly 2.4L 4-cylinder (420A) and 3.3L V6 (EGA).

Displacement 4Cyl:

2.4 Liters (2351 cc)

Horsepower 4Cyl:

Approx. 150 hp @ 5500-5800 RPM

Torque 4Cyl:

Approx. 165 lb-ft @ 4500 RPM

Displacement V6:

3.3 Liters (3301 cc)

Horsepower V6:

Approx. 180 hp @ 5000 RPM

Torque V6:

Approx. 205 lb-ft @ 3600 RPM

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Tank Capacity:

Approx. 20 gallons (76 liters)

🔧 Transmission

Standard

Transmission Type Standard:

4-speed Automatic (41TE/42LE)

Optional

Transmission Type Optional:

5-speed Manual (less common)

Features

Transmission Fluid Type:

Chrysler ATF+4 (or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 178.7 inches (4539 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 65.0 inches (1651 mm)

Wheelbase:

Approx. 112.0 inches (2845 mm)

Cargo

Cargo Volume Seats Up:

Varies significantly with seating configuration, typically around 100-150 cu ft.

Weights

Curb Weight:

Approx. 3500 - 4000 lbs (1588 - 1814 kg), depending on engine and options.

Towing Capacity:

Typically around 2000-3500 lbs (907-1588 kg) with optional towing package.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Refer to NHTSA archives for specific year/model testing, generally fair for the era.

Active Features

Available Anti-lock Braking System (ABS) on front and rear wheels.

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

Three-point seatbelts for all occupants, with pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or optional CD player with multiple speaker configurations.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Connectivity

Remote Keyless Entry:

Optional remote keyless entry system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months, or more frequently under severe use.

Engine Coolant Change:

Initial flush at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter.

Spark Plug Replacement 4Cyl:

Approx. 100,000 miles (160,000 km) with Platinum Plus spark plugs.

Spark Plug Replacement V6:

Approx. 100,000 miles (160,000 km) with Platinum Plus spark plugs.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API Certified)

Engine Oil Capacity 4Cyl:

Approx. 4.5 quarts (4.3 liters) with filter.

Engine Oil Capacity V6:

Approx. 5.0 quarts (4.7 liters) with filter.

Coolant Type:

Mopar Antifreeze/Coolant (or equivalent HOAT)

Power Steering Fluid:

ATF+4 or Pentosin CHF 11S (check specific model requirements)

Known Issues

Transmission Problems:

Common issues include solenoid pack failures, torque converter shudder, and valve body issues, particularly on higher mileage units.

Engine Mounts:

Worn engine mounts can lead to excessive vibration and noise.

Rear Wiper Motor:

Failure of the rear wiper motor or linkage.

Sliding Door Mechanisms:

Sticking or malfunctioning sliding door rollers and latches.

Suspension Wear:

Premature wear of control arm bushings and ball joints.

Heating System:

Blend door actuator failure in the HVAC system can lead to improper temperature control.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

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

Model Evolution

Generation:

This 1999 model is part of the second generation (NS, 1996-2000) of Chrysler minivans.

Design Changes Gen2:

Smoother, more aerodynamic styling compared to the first generation, improved chassis dynamics.

Production

Assembly Locations:

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

Sales Performance:

The Chrysler minivan platform was a dominant force in its segment during this period.

🏆 Awards & Recognition

Recognitions

Import Recognition:

While not a direct award, Chrysler minivans were consistently top sellers and leaders in their class for innovation and market share.