Chrysler Grand Voyager 1996 1997 Service Repair Manual

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The Chrysler Grand Voyager, produced for the 1996 and 1997 model years, is a full-size minivan designed for families and commercial users. Building on Chrysler's pioneering legacy in the minivan...

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标签: 1996 1997 Car Chrysler Grand Voyager Marine Misc Outboard Engines

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Description

The Chrysler Grand Voyager, produced for the 1996 and 1997 model years, is a full-size minivan designed for families and commercial users. Building on Chrysler's pioneering legacy in the minivan segment, this NS platform vehicle offers a spacious interior with flexible seating arrangements and a comfortable ride, making it a practical choice for everyday transportation and longer journeys. It was equipped with naturally aspirated V6 engines, including 3.0L, 3.3L, and 3.8L options, paired with a 4-speed automatic transmission, providing ample power for its class. Standard safety features included front airbags and anti-lock brakes on most models, contributing to its reputation for safety and utility. This comprehensive service and repair workshop manual provides in-depth guidance for maintaining and repairing the 1996-1997 Chrysler Grand Voyager. It covers all essential systems, including engine mechanicals, engine management, automatic transmission, brake systems, suspension, steering, and the electrical system. Detailed procedures for routine maintenance, troubleshooting, engine and transmission overhauls, and component-specific repairs for brakes, suspension, electrical, and HVAC systems are included. This extensive English-language manual, presented in a digital format, is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Grand Voyager

Year:

1996-1997

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Full-size Minivan

Target Audience:

Families, commercial users

Competitive Analysis

Competitors:

Ford Windstar, Chevrolet Venture, Dodge Grand Caravan, Plymouth Grand Voyager

Key Features

Versatility:

Spacious interior, flexible seating arrangements, Stow 'n Go (later models, but foundation laid)

Comfort:

Comfortable ride, family-oriented amenities

Engine Options:

V6 powertrain offered strong performance for its class

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service, Repair, and Workshop Manual

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

All engine types, overhaul, repair, diagnosis

Engine Management:

Fuel injection, ignition, emissions control, ECU diagnosis

Transmission Automatic:

Service, repair, diagnosis, fluid service

Transmission Manual:

Service, repair, diagnosis, fluid service

Brake System:

Hydraulic system, ABS, disc and drum brakes, parking brake

Suspension:

Front and rear suspension, struts, shocks, control arms, alignment

Steering:

Power steering system, steering column, rack and pinion

Electrical System:

Wiring diagrams, charging system, starting system, lighting, accessories

HVAC System:

Air conditioning, heating, ventilation, blower motor, refrigerant service

Body Interior:

Seating, trim, door panels, headliner, body shell repair

Body Exterior:

Bumpers, fenders, hood, doors, tailgate, glass, seals

Safety Systems:

Airbags, seat belts, passive restraint systems

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, tune-ups, fluid checks

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting guides

Engine Overhaul:

Complete engine rebuild procedures, component replacement

Transmission Rebuild:

Detailed steps for automatic transmission disassembly and assembly

Brake Service:

Pad and rotor replacement, caliper overhaul, bleeding procedures

Suspension Repair:

Component replacement, strut and shock absorber installation

Electrical Diagnosis:

Component testing, wiring harness repair, electrical connector service

HVAC Service:

Refrigerant recharging, component replacement, leak detection

Body Repair:

Panel replacement, dent repair, rust mitigation

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance to full rebuilds and diagnostics.

📊 Manual Specifications

File Format

File Quality:

High-resolution scans, often searchable text.

Print Quality

Print Readability:

Clear and easy to read, suitable for printing.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

3.0L V6 (Mitsubishi 6G72)

Displacement 1:

2972 cc

Horsepower 1:

142 hp @ 5000 rpm

Torque 1:

171 lb-ft @ 3500 rpm

Engine Code 2:

3.3L V6 (EGA)

Displacement 2:

3301 cc

Horsepower 2:

156 hp @ 4850 rpm

Torque 2:

185 lb-ft @ 3250 rpm

Engine Code 3:

3.8L V6 (L32)

Displacement 3:

3778 cc

Horsepower 3:

168 hp @ 4400 rpm

Torque 3:

227 lb-ft @ 3200 rpm

Performance

Induction Type:

Naturally Aspirated

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic (41TE/42LE)

Optional

Transmission Type:

Features

Transmission Control:

Electronic control for shift quality and diagnostics

Transmission Fluid Type:

ATF+4 (Mopar)

📐 Dimensions

Exterior

Length:

Approx. 195.7 inches

Width:

Approx. 72.1 inches

Height:

Approx. 68.7 inches

Wheelbase:

Approx. 119.3 inches

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 21.0 cu ft

Cargo Volume Behind 2Nd Row:

Approx. 77.7 cu ft

Cargo Volume Behind 1St Row:

Approx. 140.0 cu ft

Weights

Curb Weight:

Approx. 3800 - 4100 lbs

Gross Vehicle Weight Rating:

Approx. 5400 - 5800 lbs

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4/5 stars (depending on configuration)

Active Features

Standard on most models

Traction Control:

Optional

Passive Features

Airbags Front:

Driver and Passenger Airbags (Standard)

Seat Belts:

All seating positions equipped with three-point seat belts

Child Seat Anchors:

LATCH system not standard in this era, but manual may cover proper seat belt usage for child seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or optional CD player. Basic speaker systems.

Navigation:

Not available

Driver Assistance

Cruise Control:

Standard on most models

Parking Assist:

Not available

Connectivity

Bluetooth:

Not available

Auxiliary Input:

Not available

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Replacement:

Inspect every 7,500 miles, replace as needed (typically every 15,000-30,000 miles).

Spark Plug Replacement:

Varies by engine: 3.0L V6 (approx. 60,000 miles), 3.3L/3.8L V6 (approx. 100,000 miles with platinum plugs).

Transmission Fluid Change:

Every 30,000 - 60,000 miles, or per severe service schedule.

Fluid Specifications

Engine Oil:

SAE 5W-30 or 5W-20 (check owner's manual for specific viscosity based on climate and engine).

Coolant:

Chrysler HOAT (Hybrid Organic Additive Technology) or equivalent OAT coolant, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF+3 or ATF+4 (Mopar)

Known Issues

Transmission Failure:

The 41TE/42LE transmission could be prone to failure if not properly maintained, particularly the torque converter clutch and input/output shafts.

Head Gasket Leaks:

Some 3.3L and 3.8L engines may develop head gasket leaks, especially at higher mileage.

Electrical Gremlins:

As with many vehicles of this era, aging wiring harnesses, ground points, and modules can lead to various electrical issues.

Rear Main Seal Leaks:

Common leak point on many Chrysler engines.

Heater Core Leaks:

The location of the heater core within the dashboard can make replacement labor-intensive.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

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

Model Evolution

Generation Ns:

This represents the second generation of Chrysler minivans (originally launched as the NS platform).

Key Updates 1996:

Refreshed styling, improved safety features, and new powertrain options introduced for 1996.

Production

Assembly Location:

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

Production Years:

1996-2000 (for this generation)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Voyager/Caravan platform was a frequent recipient of Car and Driver's 10Best list in its earlier generations, establishing its dominance. While this specific generation may not have repeated the 10Best honor as consistently, it maintained a strong market presence.

Ratings

Kbb Consumer Ratings:

Historically strong consumer ratings for practicality and value.

Certifications

Safety Standards:

Meets all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for the model years covered.