Plymouth Voyager 1996-1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Plymouth Model: Voyager Years Covered By Manual: 1996-1997 Broader Model Coverage Indicated: 1996-2000 Codes Chassis Code: NS (Minivan platform) 👋 Introduction Market Position Vehicle Segment:...

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标签: 1996 1997 Car Cars Grand Voyager Plymouth Voyager

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Description

🏷️ Basic Information

Identification

Make:

Plymouth

Model:

Voyager

Years Covered By Manual:

1996-1997

Broader Model Coverage Indicated:

1996-2000

Codes

Chassis Code:

NS (Minivan platform)

👋 Introduction

Market Position

Vehicle Segment:

Full-size minivan, a dominant segment in the automotive market during the mid-to-late 1990s.

Target Audience:

Families and individuals requiring flexible passenger and cargo hauling capabilities.

Competitive Analysis

Key Competitors:

Ford Windstar, Chevrolet Venture, Pontiac Trans Sport, Oldsmobile Silhouette, Mazda MPV, Honda Odyssey.

Key Features

Versatility:

Flexible seating arrangements, ample cargo space, often available with Stow 'n Go or similar seating systems in later generations.

Powertrain Options:

Reliable V6 engine options, capable of towing and everyday driving.

Practicality:

Designed for practicality, ease of use, and passenger comfort.

📋 Manual Details

Coverage Areas

Primary Coverage Years:

1996-1997

Secondary Coverage Indication:

1996-2000

Page Count

Estimated Page Count:

High (Detailed factory specifications imply extensive content, likely exceeding 1500 pages across multiple volumes for a comprehensive factory service manual)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

File Format:

Compatibility:

Windows (95, 98, ME, XP, Vista, 7), Linux, MAC

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, cooling, lubrication, fuel, ignition, exhaust, powertrain control module (PCM)

Transmission:

Automatic transmission (e.g., 41TE/42LE), hydraulic controls, electronic controls, overhaul procedures

Drivetrain:

Front-wheel drive system, CV joints, differentials

Brakes:

Front and rear disc brakes, anti-lock braking system (ABS) components and diagnostics, hydraulic lines, parking brake

Suspension:

Front independent suspension (MacPherson strut), rear suspension, shock absorbers, springs, control arms, steering linkage

Steering:

Power steering system, steering column, steering gear, components, and diagnosis

Electrical System:

Battery, charging system, starter, lighting system, power windows, locks, mirrors, wiper system, horn, trailer wiring

Body And Interior:

Body panels, doors, hinges, latches, interior trim, seating, dashboard, headliner, glass, sunroof (if applicable)

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant handling, components, diagnosis, and repair

Restraint Systems:

Airbag system components, operation, and replacement procedures

Diagnostics:

On-board diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, brake pad replacement

Troubleshooting:

System-specific diagnostic flowcharts, symptom-based troubleshooting guides, electrical circuit diagrams and pinpoint tests

Repair:

Engine component removal and installation, transmission overhaul, brake system repair, suspension component replacement, electrical component diagnosis and replacement

Installation:

Component installation, body panel alignment, accessory installation

Rebuilding:

Engine component rebuilding, transmission rebuilding (detailed procedures)

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to advanced diagnostics and complete vehicle rebuilds, suitable for professional technicians and advanced DIYers.

Detail Level:

Includes detailed torque specifications, electrical schematics, diagnostic procedures, and component tolerances.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans or digitally created PDF, ensuring clarity of text and diagrams. Searchable text is a high probability for factory service manuals.

Printable:

Yes (PDF format allows for printing of specific sections or the entire manual).

Binding Type

Binding Type For Original:

Likely a multi-volume set with durable ring binding or stapled booklets, typical for factory manuals.

Paper Type

Paper Type For Original:

High-quality, durable paper designed to withstand shop environments.

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

3.0L (181 cu in) V6 (6G72 Mitsubishi-sourced)

Engine Configuration:

SOHC V6

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Horsepower Approximate:

150 hp @ 5000 rpm

Torque Approximate:

180 lb-ft @ 3750 rpm

Secondary Engine Option

Engine Displacement:

3.3L (203 cu in) V6 (EGA/EGB Chrysler LA-based)

Engine Configuration:

Overhead Valve (OHV) V6

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Horsepower Approximate:

158 hp @ 4700 rpm

Torque Approximate:

190 lb-ft @ 3750 rpm

Performance

0-60 Mph Approximate:

10.5 - 11.5 seconds (depending on engine and configuration)

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity Approximate:

15-18 gallons

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic

Transmission Model Codes:

41TE / 42LE

Optional

Optional Transmission Type:

None typically offered for these model years; the automatic was standard.

Features

Transmission Control:

Electronic control with torque converter lock-up

Transmission Fluid Specification:

ATF+4 (often recommended, check manual for specific OE fluid for 1996-97)

📐 Dimensions

Exterior

Length Approximate:

189.4 inches (Standard Wheelbase), 201.5 inches (Long Wheelbase)

Width Approximate:

72.4 inches

Height Approximate:

68.0 inches

Wheelbase Approximate:

111.9 inches (Standard), 119.2 inches (Long)

Interior

Passenger Capacity:

7-8 passengers

Cargo

Cargo Volume Behind 3Rd Row Approximate:

38.5 cu ft (Standard Wheelbase)

Cargo Volume Behind 1St Row Approximate:

146.9 cu ft (Standard Wheelbase)

Weights

Curb Weight Approximate:

3,700 - 4,100 lbs

Gross Vehicle Weight Rating Gvwr Approximate:

5,500 - 5,800 lbs

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver Rating:

Likely 4 stars (for 1996 models based on historical data, though specific 1996-97 Voyager ratings can vary)

NHTSA Frontal Impact Passenger Rating:

Likely 4 stars (for 1996 models based on historical data)

IIHS Crash Test Ratings:

Varies by specific test and year; detailed specific ratings should be verified with IIHS archives.

Active Features

Available (Standard on some trims, optional on others)

Traction Control:

Optional on some models

Passive Features

Airbags:

Driver and front passenger airbags (standard)

Seatbelts:

Three-point seatbelts for all outboard occupants, lap belts for center rear occupants.

Child Safety Anchors:

LATCH system not standard; child seat tether straps likely present.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette or CD player, optional premium sound systems. Manual covers wiring and component replacement.

Driver Assistance

Cruise Control:

Standard or optional on most models. Manual details system operation and diagnostics.

Connectivity

Trailer Wiring:

Provisions for trailer towing and associated wiring harness. Manual details the connector pinouts and functionality.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months (traditional interval). Consult manual for potential synthetic oil extended intervals.

Engine Coolant Flush Interval:

Every 30,000 miles or 2-3 years (typical for the era, check manual).

Transmission Fluid Change Interval:

Every 30,000-60,000 miles, or more frequently under severe service. Critical to check manual for specific recommendations.

Spark Plug Replacement Interval:

Approximately 60,000-100,000 miles depending on spark plug type (conventional, platinum, or iridium).

Fluid Specifications

Engine Oil Specification:

SAE 5W-30 (API Service SG or higher for 3.0L, check manual for 3.3L)

Engine Coolant Specification:

Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific Mopar coolant type.

Power Steering Fluid:

ATF+3 or ATF+4 recommended (check manual for exact specification)

Brake Fluid:

DOT 3 or DOT 4 (check manual)

Known Issues

Head Gaskets:

Some Chrysler V6 engines of this era were prone to head gasket issues, particularly the 3.3L and 3.8L. Manual will detail inspection and replacement.

Transmission Issues:

The 41TE/42LE transmissions could experience issues with solenoids, clutches, and torque converters if not properly maintained. Manual provides diagnostic and repair procedures.

Power Window Motors:

Intermittent or failed power window operation can occur. Manual covers diagnosis of regulators and motors.

Wheel Bearings:

Front wheel bearings can wear out, causing noise. Manual covers replacement procedures.

Evaporative Emission Control System:

EVAP system leaks (e.g., vent solenoid, charcoal canister) can cause check engine lights. Manual provides diagnostic pathways.

📚 Vehicle History

Brand Heritage

Plymouth Brand Context:

Plymouth was a Chrysler Corporation brand known for offering value-oriented vehicles.

Model Evolution

Platform Generation:

NS platform (1996-2000), a significant redesign from the previous S platform.

Design Changes From Previous:

More aerodynamic styling, improved interior ergonomics, increased safety features, and the introduction of driver-side airbags.

Production

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant) and St. Louis, Missouri, USA.

Production Years For Ns Platform:

1996-2000

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

Voyager/Grand Voyager models often appeared on Car and Driver's 10 Best lists in earlier generations, establishing its market presence. Specific 1996-97 awards not readily documented but the platform was competitive.

Ratings

Consumer Reports Reliability:

Reliability ratings for this era of Chrysler minivans were often mixed; consulting Consumer Reports archives for specific model years is recommended. The manual is essential for proactive maintenance.