Segment:
Full-size minivan, popular for family transport and versatility.
Competitors:
Dominated the minivan segment alongside competitors like the Ford Windstar, Chevrolet Venture/Lumina APV, and Japanese minivans such as the Toyota Sienna and Honda Odyssey.
Features:
Spacious interior, flexible seating configurations, available all-wheel drive (AWD), Stow 'n Go seating (introduced later, but the precursor of flexibility was key), powerful V6 engine options.
Coverage:
All mechanical and electrical systems, maintenance, repair, diagnostics, and troubleshooting for Chrysler Voyager models manufactured between 1996 and 1999.
Pages:
Estimated 1500-2000+ pages (typical for comprehensive service manuals of this era)
Type:
Factory Service Manual / Workshop Manual
Format:
Likely available as a digital PDF or a multi-volume printed set.
Powertrain:
Engine (3.0L, 3.3L, 3.8L V6), cooling system, fuel system, exhaust system, ignition system, starting and charging system.
Transmission:
Automatic transmissions (e.g., A604/41TE, A670/42LE), including removal, installation, overhaul, diagnostics, and fluid specifications.
Chassis:
Suspension (front and rear), steering system, brake system (front disc, rear drum/disc), anti-lock braking system (ABS).
Electrical:
Wiring diagrams, charging system, starting system, lighting, instruments, power accessories, HVAC controls, body electronics, diagnostic trouble codes (DTCs).
Body:
Body structure, exterior trim, interior trim, doors, windows, liftgate, seating systems, HVAC (heating, ventilation, and air conditioning).
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, transmission, brake), filter replacements, belt inspections and replacements, spark plug replacement.
Repair:
Engine repair (cylinder head, pistons, crankshaft), transmission overhaul, brake caliper and rotor replacement, suspension component replacement, steering rack repair, HVAC component replacement.
Diagnostics:
Troubleshooting guides based on symptoms, diagnostic trouble code (DTC) interpretation and resolution, electrical system testing using multimeters and oscilloscopes.
Special Tools:
Identification and usage of specialized Chrysler tools required for specific repair procedures.
Depth:
Comprehensive, covering from basic routine maintenance to in-depth engine and transmission overhauls, electrical diagnostics, and bodywork.
Digital Quality:
High-resolution scans or digitally created documents with searchable text for ease of navigation. Clear images and diagrams.
Print Features:
Professionally printed, durable binding, clear text and diagrams, often spiral-bound or case-bound for lay-flat use.
Binding:
Typically case-bound or spiral-bound for durability and ease of use in a workshop environment.
Paper Quality:
Durable, matte-finish paper to reduce glare and withstand workshop conditions.
Engine 1 Variant:
3.0L V6 (Mitsubishi 6G72 SOHC)
Engine 1 Displacement:
2972 cc
Engine 1 Horsepower:
Approx. 140-147 hp @ 5000 rpm
Engine 1 Torque:
Approx. 170-175 lb-ft @ 3000 rpm
Engine 2 Variant:
3.3L V6 (Chrysler EGH/EGQ SOHC)
Engine 2 Displacement:
3301 cc
Engine 2 Horsepower:
Approx. 158-170 hp @ 5000 rpm
Engine 2 Torque:
Approx. 195-200 lb-ft @ 3000 rpm
Engine 3 Variant:
3.8L V6 (Chrysler EGT SOHC)
Engine 3 Displacement:
3778 cc
Engine 3 Horsepower:
Approx. 166-180 hp @ 4400-4600 rpm
Engine 3 Torque:
Approx. 228-230 lb-ft @ 3200-3600 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI) - Multi-port fuel injection (MPFI).
Recommended Fuel:
Unleaded gasoline, 87 octane (Octane Rating).
Transmission Type:
4-speed automatic.
AWD Availability:
All-Wheel Drive (AWD) was an option on some models/trims, particularly with the 3.8L engine.
Transmission Codes:
A604 (41TE), A670 (42LE) - Common Chrysler transmissions of the era.
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid +4) or equivalent meeting Chrysler MS-9602 specification. Consult manual for exact fill.
NHTSA Frontal Impact Driver:
4-star (for earlier models in this range, specifications may vary by year)
NHTSA Frontal Impact Passenger:
4-star (for earlier models in this range, specifications may vary by year)
ABS:
Anti-lock Braking System (ABS) was standard or optional depending on trim and year.
Airbags:
Driver and front passenger airbags were standard.
Seatbelts:
Front seatbelt pretensioners, all seating positions with lap and shoulder belts.
Audio System:
Standard AM/FM stereo with cassette player, optional CD player. Available premium sound systems with multiple speakers.
Rear Entertainment:
Optional rear-seat entertainment systems, including video cassette players (VCP) and flip-down screens, were available on higher trims.
Cruise Control:
Standard on most models.
Power Accessories:
Power windows, power locks, power mirrors were widely available and often standard on higher trims.
Remote Keyless Entry:
Available on many models, often bundled with power options.
Oil Change Interval:
Every 3,000 to 5,000 miles or 3 to 6 months, depending on driving conditions. Consult owner's manual for specific recommendations.
Transmission Fluid Change Interval:
Typically every 30,000 to 60,000 miles. Crucial for longevity; manual will detail specific intervals.
Coolant Change Interval:
First flush at 50,000 miles, then every 30,000 miles or 2 years thereafter. Use specified coolant type.
Spark Plug Replacement:
Varies by engine; typically 60,000 to 100,000 miles for platinum or iridium plugs.
Engine Oil Type:
SAE 5W-30 or 10W-30 (depending on ambient temperature). Consult manual for precise viscosity and API service classification (e.g., API SM/SN).
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT or equivalent meeting MS-7170 or MS-9769.
Brake Fluid Type:
DOT 3 or DOT 4, meeting Federal Motor Vehicle Safety Standard (FMVSS) No. 116.
Common Problems:
Transmission solenoid failure (especially in early 41TE), EGR valve clogging, power steering pump leaks, heater core issues, radiator leaks, AC system performance degradation, wheel bearing noise, liftgate strut failure.
Diagnostic Tips:
Intermittent electrical issues can be common; check grounds and connectors. Listen for specific transmission clunks or slipping. Monitor engine for misfires and check engine lights.
Chrysler Legacy:
Chrysler established itself as a leader in the minivan market with the introduction of the original Dodge Caravan/Plymouth Voyager in the mid-1980s, a segment it largely pioneered.
Voyager Generation:
This period covers the second generation (NS platform, 1996-2000). Key changes included a more aerodynamic design, improved safety features, and updated powertrains. The Voyager nameplate was typically used for export markets or specific trim levels within the Chrysler brand.
Manufacturing Locations:
Primarily Windsor, Ontario, Canada (Chrysler Canada minivan assembly plant).
Car And Driver 10Best:
While specific Voyager models from these years might not have consistently made the 10Best lists, Chrysler minivans were frequently recognized for their utility and value in this period.
Consumer Reports:
Consumer Reports ratings varied for these model years; the manual will be invaluable for owners to address common wear items and maintain reliability.
Certification Standards:
All repair and maintenance procedures detailed in the manual adhere to or exceed SAE (Society of Automotive Engineers) standards and Chrysler's own engineering specifications.
