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Chrysler Voyager 1996-2003 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Generation: GS (Second Generation) Production Years: 1996-2003 Codes Platform Code: NS/GS 👋 Introduction Market Position Segment: Minivan Target Audience: Families, individuals needing...
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Chrysler Voyager 1996-2003 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Generation:
GS (Second Generation)
Production Years:
1996-2003
Codes
Platform Code:
NS/GS
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Families, individuals needing versatile cargo and passenger transport
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Lumina APV, Pontiac Trans Sport, Dodge Caravan/Grand Caravan
Key Features
Distinguishing Features:
Front-wheel drive (optional All-Wheel Drive on some models outside US), spacious interior with multiple seating configurations, available Stow 'n Go seating (later models), smooth ride, family-oriented features.
📋 Manual Details
Coverage Areas
Regions Covered:
North America (primarily US, Canada, Mexico), Europe (as Chrysler Grand Voyager)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Authorized Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (2.4L DOHC, 3.0L SOHC V6, 3.3L OHV V6, 3.8L OHV V6), Transmission (3-speed Automatic 32RH, 4-speed Automatic 41TE/42LE)
Chassis:
Suspension (front MacPherson strut, rear twist-beam axle with Watt's linkage), Steering (power rack and pinion), Brakes (front disc, rear drum/disc depending on model)
Electrical:
Wiring diagrams, lighting, instrumentation, power windows, locks, mirrors, climate control, audio system, remote keyless entry, optional entertainment systems
Body:
Exterior panels, interior trim, seating, doors, liftgate, HVAC system, body sealing, corrosion protection
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake, transmission), filter replacements, spark plug replacement, battery service
Repair:
Engine overhaul, transmission service and rebuild, brake system repair, suspension component replacement, steering system repair, electrical component diagnosis and repair, body panel repair and replacement
Diagnostics:
Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) and their meanings, procedures for using diagnostic tools (e.g., OBD-II scanner)
Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 1 Variant:
2.4L DOHC I4 (GEMA engine)
Engine 1 Power:
Approx. 150 hp @ 5200 rpm
Engine 1 Torque:
Approx. 170 lb-ft @ 4000 rpm
Engine 2 Variant:
3.0L SOHC V6 (Mitsubishi 6G72)
Engine 2 Power:
Approx. 150 hp @ 5000 rpm
Engine 2 Torque:
Approx. 180 lb-ft @ 3700 rpm
Engine 3 Variant:
3.3L OHV V6 (Chrysler EDB/EDZ)
Engine 3 Power:
Approx. 160-170 hp @ 4700-5000 rpm
Engine 3 Torque:
Approx. 190-200 lb-ft @ 3200-3500 rpm
Engine 4 Variant:
3.8L OHV V6 (Chrysler EGH/EGA)
Engine 4 Power:
Approx. 180 hp @ 4500-4700 rpm
Engine 4 Torque:
Approx. 230-240 lb-ft @ 3200-3500 rpm
Performance
0 60 Mph Times:
10.0-12.5 seconds (depending on engine and configuration)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 octane (minimum)
🔧 Transmission
Standard
Transmission 1:
3-speed Automatic (Chrysler 32RH)
Optional
Transmission 2:
4-speed Automatic (Chrysler 41TE/42LE)
Features
Transmission Features:
Lock-up torque converter, electronic control (41TE/42LE)
📐 Dimensions
Exterior
Wheelbase:
Approx. 119.3 inches (3030 mm)
Length:
Approx. 194.5 inches (4940 mm) (Standard Wheelbase), Approx. 204.0 inches (5182 mm) (Long Wheelbase - Grand Voyager)
Width:
Approx. 72.0 inches (1829 mm)
Height:
Approx. 68.0 inches (1727 mm)
Weights
Curb Weight:
Approx. 3800-4300 lbs (1724-1950 kg) (depending on engine and configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4-star (driver), 4-star (passenger) in early tests
Active Features
ABS:
Standard on most models
Traction Control:
Optional on some models
Passive Features
Airbags:
Driver and front passenger airbags standard
Seatbelts:
3-point seatbelts for all occupants, front seatbelt pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and/or CD player, optional premium audio systems
Rear Seat Entertainment:
Optional rear-seat video monitor and VCR/DVD player available on higher trims
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Remote Keyless Entry:
Optional
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months (whichever comes first) under normal driving conditions. Severe duty may require shorter intervals.
Transmission Fluid Change Interval:
Every 30,000-60,000 miles or 36-48 months, depending on driving conditions and transmission type (consult manual for specifics).
Coolant Flush Interval:
Every 30,000 miles or 24 months (for conventional coolant). Longer intervals may apply for HOAT or OAT coolants if used.
Spark Plug Replacement:
Typically 100,000 miles for iridium/platinum plugs, earlier for standard copper plugs (check specific engine).
Fluid Specifications
Engine Oil Specification:
API SN or later, SAE 5W-30 (check specific engine recommendation, synthetic blend often recommended)
Coolant Specification:
Chrysler Composite Organic Acid Technology (COAT) or equivalent (typically Mopar OAT 68157995AB or equivalent)
Transmission Fluid Specification:
ATF+4 (Mopar 05013457AA or equivalent) for 41TE/42LE. ATF+3 for 32RH.
Brake Fluid Specification:
DOT 3
Known Issues
Common Problems:
Transmission solenoid pack failure (especially 41TE/42LE), intake manifold gasket leaks, cooling system leaks (heater core, radiator), power steering pump noise, EGR valve issues, rear axle seal leaks, automatic sliding door mechanism issues.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in the 1980s, establishing a benchmark for family vehicles.
Model Evolution
Generation Development:
The GS generation (1996-2000) was a significant redesign from the previous AS platform, featuring a more aerodynamic body, improved safety, and updated powertrains. It was succeeded by the RS platform (2001-2007) which saw further refinements and the introduction of Stow 'n Go seating.
Production
Manufacturing Location:
Windsor, Ontario, Canada (Chrysler Canada Inc.)
Market Success:
The Voyager and its sibling models (Dodge Caravan, Plymouth Voyager) were consistently among the best-selling minivans in North America during this period, known for their practicality and value.
🏆 Awards & Recognition
Recognitions
Wards Auto Hall Of Fame Powertrain:
Chrysler's V6 engines (3.3L and 3.8L) received accolades for their smoothness and power delivery during this era.
Ratings
Consumer Reports Reliability:
Reliability varied by model year and specific component; generally considered average to below average for the period, particularly concerning transmission longevity.
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