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Chrysler

Chrysler Voyager 1996-2001 Workshop Repair Service Manual

Chrysler Voyager 1996-2001 Workshop Repair Service Manual

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$16.99
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Vehicle data plateRef 428421
Brand
Chrysler
Vehicle
Cars
Models covered
200, Voyager
Years
1996, 1997, 1998, 1999, 2000, 2001
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Voyager
Generation:
GS (Second Generation)
Production Years:
1996-2001
Codes
Chassis Code:
GS
👋 Introduction
Market Position
Target Audience:
Mechanical technicians and knowledgeable vehicle owners.
Competitive Analysis
Value Proposition:
Enables owners to perform maintenance and repairs themselves, saving costs and gaining knowledge.
Key Features
Reliability:
Provides the most reliable information available for servicing the vehicle.
Completeness:
Contains all necessary instructions for any repair the vehicle may require.
Dealer Equivalency:
Includes specifications and procedures comparable to authorized dealer service departments.
Emphasis Symbols:
Uses WARNING, CAUTION, and NOTE to highlight critical information.
📋 Manual Details
Coverage Areas
Covered Years:
1996, 1997, 1998, 1999, 2000, 2001
Vehicle Type:
Minivan
Page Count
Estimated Page Count:
Not Specified, but comprehensive
Manual Type
Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage including removal, installation, and internal component overhaul.
Transmission:
Detailed repair and overhaul procedures for automatic transmissions.
Fuel System:
Covers fuel pump, injectors, lines, and emissions controls.
Ignition System:
Diagnostic and repair procedures for ignition coils, spark plugs, and timing.
Lubrication System:
Oil pump, filter, and lubrication circuit maintenance.
Exhaust System:
Components, diagnostics, and repair of exhaust manifolds, pipes, and mufflers.
Electrical System:
Wiring diagrams, component testing, charging system, starting system, lighting, and accessories.
Body:
Exterior and interior body repair, panel replacement, glass, and trim.
Brakes:
Inspection, repair, and maintenance of hydraulic system, ABS, rotors, pads, and calipers.
Suspension Steering:
Covers struts, shocks, control arms, ball joints, tie rods, and power steering.
Heating Air Conditioning:
Component identification, diagnosis, and service of HVAC system.
Wheels Tires:
Specifications, mounting, and rotation.
Procedures Included
Maintenance:
Routine service, fluid changes, filter replacements, and inspections.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common issues.
Repair:
Step-by-step instructions for component replacement and repair.
Overhaul:
Detailed procedures for engine and transmission rebuilds.
Diagnostics:
Emphasis on special aspects of product repair and component functions.
Tune Ups:
Procedures for optimizing engine performance.
Removal Installation:
Instructions for removing and installing major components.
Assemblies Disassemblies:
Detailed breakdown and reassembly of vehicle systems.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and knowledgeable DIYers.
Special Tools:
Identifies and illustrates Chrysler special tool numbers where required.
Proprietary Components:
Includes instructions from respective component manufacturers for proprietary parts.
Safety Emphasis:
Highlights safety precautions, including the use of torque wrenches.
📊 Manual Specifications
File Format
Format:
PDF
Delivery Method:
Electronic Delivery via Email
Delivery Speed:
Fast and Free
Print Quality
Printability:
Yes, printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
Searchability
Text Search:
Likely searchable text within the PDF (standard for professional manuals).
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely includes 2.4L I4 (DOHC, 16-valve, 'EDZ') and 3.0L V6 (SOHC, 12-valve, '6G72') and 3.3L V6 (SOHC, 12-valve, 'EGA'). Specifics depend on model year.
Engine Codes:
EDZ (2.4L), 6G72 (3.0L V6), EGA (3.3L V6). Specific year application varies.
Performance
Horsepower Range:
Approximately 150 hp (2.4L) to 180 hp (3.3L V6). Exact figures vary by engine and year.
Torque Range:
Approximately 160 lb-ft (2.4L) to 200 lb-ft (3.3L V6). Exact figures vary by engine and year.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded Gasoline.
Engine Management
ECM:
Engine Control Module (ECM) type and location described.
🔧 Transmission
Standard
Transmission Type Standard:
Likely a 3-speed or 4-speed automatic transmission (e.g., A604/41TE or A670/42LE).
Optional
Transmission Type Optional:
Depending on year and engine, a different automatic variant might be available.
Features
Shift Control:
Electronic shift control covered.
Fluid Specifications
Transmission Fluid:
Specifications for ATF+4 or equivalent fluids will be detailed.
📐 Dimensions
Exterior
Wheelbase:
Approximately 112.2 inches (2850 mm).
Length:
Approximately 178.4 inches (4531 mm) to 181.7 inches (4615 mm) depending on configuration.
Cargo
Cargo Volume:
Significant cargo capacity, configurable with folding/removable seats.
Weights
Curb Weight:
Typically ranges from 3,500 to 4,000 lbs, depending on engine and equipment.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Varied by year, generally 4-star for driver and passenger.
IIHS Side Impact:
Varied by year, 'Acceptable' to 'Good'.
Active Features
ABS:
Anti-lock Braking System availability and function covered.
Passive Features
Airbags:
Driver and front passenger airbags; potential for side airbags in later models.
Seatbelts:
Seatbelt system description and maintenance.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with cassette and/or CD player. Optional premium audio systems.
Navigation:
Limited or no factory navigation systems typically available for this generation.
Driver Assistance
Cruise Control:
Standard feature on most models.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were common options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 to 7,500 miles depending on oil type and driving conditions (manual will specify).
Transmission Fluid Change:
Recommended every 30,000 to 60,000 miles (manual will provide specific intervals).
Fluid Specifications
Engine Oil:
Typically SAE 5W-30 or 10W-30 depending on ambient temperature (manual will confirm).
Coolant:
Chrysler's HOAT (Hybrid Organic Acid Technology) coolant or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Transmission Problems:
Certain automatic transmission models (especially early versions of the 41TE) were prone to solenoid issues and fluid leaks.
Cooling System:
Overheating due to radiator or water pump failures can occur. Intake manifold gasket leaks are also common on V6 engines.
Electrical Gremlins:
Common for this era of vehicle, including issues with power windows, door locks, and instrument clusters.
Spark Plugs
Spark Plug Type:
Typically platinum or iridium tipped spark plugs, with specific part numbers provided in the manual.
📚 Vehicle History
Brand Heritage
Chrysler Minivan:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager.
Model Evolution
Gs Generation:
The second generation (GS) saw significant updates in styling, safety, and powertrain compared to the first generation.
Production
Manufacturing Location:
Primarily St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Car And Driver:
Voyager and its siblings (Caravan, Town & Country) were frequently named to Car and Driver's Ten Best lists in their initial years, though specific mentions for the 1996-2001 generation may vary.

Delivery & file format

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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