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Plymouth

Plymouth Voyager 1996-2000 Service Repair Manual

Plymouth Voyager 1996-2000 Service Repair Manual

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Vehicle data plateRef 262040
Brand
Plymouth
Vehicle
Cars
Models covered
Voyager
Years
1996, 1997, 1998, 1999, 2000
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:
Plymouth
Model:
Voyager
Codes
Platform:
NS (Chrysler Minivan Platform)
Generation
Generation:
Third Generation
👋 Introduction
Market Position
Positioning:
The Plymouth Voyager was a highly popular minivan, a segment that Chrysler largely defined. This service manual positions itself as the definitive resource for owners and independent repair shops aiming to maintain and repair these vehicles to factory standards.
Competitive Analysis
Competition:
Competed directly with the Ford Windstar, Chevrolet Venture, Pontiac Montana, and Honda Odyssey. The factory service manual offers an advantage over generic aftermarket guides due to its specific and detailed factory-level information.
Key Features
Value Proposition:
Provides dealer-level diagnostic and repair information, empowering DIY enthusiasts and independent mechanics with the knowledge to service the entire vehicle, saving on dealership labor costs.
📋 Manual Details
Coverage Areas
Years Covered:
1996, 1997, 1998, 1999, 2000
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, drivetrain, exhaust system
Chassis:
Suspension, steering, brakes, wheels, tires
Electrical:
Wiring diagrams, lighting, charging system, ignition system, starter, instruments, accessories, body electronics, power windows, power locks, HVAC controls
Body:
Body panels, doors, windows, seats, interior trim, exterior trim, HVAC system, climate control
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, fluid checks and changes, filter replacements, lubrication, tune-ups
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair, body panel repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit testing
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls, including electrical schematics and diagnostic procedures
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans of original factory documentation
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Compatibility
Operating Systems:
Windows 95/98/ME/XP/Vista/7, Linux, MAC OS
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.4L DOHC 16-Valve 4-Cylinder (ID: EDZ - Turbocharged in some markets/variants, but typically naturally aspirated for Voyager)
Engine 2:
3.0L SOHC 12-Valve V6 (Mitsubishi 6G72)
Engine 3:
3.3L OHV 12-Valve V6 (Chrysler EFA)
Engine 4:
3.8L OHV 12-Valve V6 (Chrysler EGH)
Performance
Horsepower Range:
150 hp to 180 hp (depending on engine)
Torque Range:
180 lb-ft to 230 lb-ft (depending on engine)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission 1:
4-Speed Automatic (Chrysler 41TE/42LE)
Optional
Transmission 2:
No manual transmission offered for this generation in North America.
Features
Transmission Features:
Electronically controlled, overdrive gear, torque converter lock-up
📐 Dimensions
Exterior
Wheelbase Standard:
111.8 inches
Wheelbase Long Wheelbase:
119.3 inches (Grand Voyager)
Length:
187.1 inches (Standard Wheelbase) / 194.6 inches (Long Wheelbase)
Interior
Seating Capacity:
7 Passengers (typically 2-2-3 configuration)
Cargo
Cargo Volume:
Varies by seating configuration and wheelbase, often exceeding 150 cubic feet with rear seats removed.
Weights
Curb Weight Range:
Approx. 3,800 - 4,200 lbs (depending on engine and configuration)
🛡️ Safety Features
Ratings
NHTSA Front Driver Side Impact:
Likely 4-star (for 1996-1999 models tested)
NHTSA Front Passenger Side Impact:
Likely 4-star (for 1996-1999 models tested)
IIHS Frontal Offset:
Acceptable (for models tested)
Active Features
ABS:
Standard on most models, optional on some base trims.
Traction Control:
Optional on V6 models, often linked with ABS.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seat Belts:
All seating positions equipped with three-point seat belts. Driver and front passenger have pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player and CD player option. Speaker configurations varied by trim level.
Rear Entertainment:
Optional rear-seat video monitor and VHS player available on higher trims or as dealer-installed accessories.
Driver Assistance
Cruise Control:
Standard on most models.
Keyless Entry:
Available on higher trim levels or as an option.
Connectivity
Connectivity Features:
Limited by era; primarily focused on basic vehicle functions and entertainment. No factory Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 miles or 6 months (check owner's manual for specific engine/oil type recommendations).
Transmission Fluid Change:
Recommended every 30,000-60,000 miles, depending on driving conditions (consult manual).
Coolant Flush:
Typically every 30,000-50,000 miles or 2-3 years.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 10W-30 (depending on ambient temperature, refer to manual for specific engine)
Transmission Fluid Type:
ATF+4 (Chrysler Mopar)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (typically pink or orange)
Known Issues
Common Problems:
Transmission failure (especially early 4-speed automatics), EGR valve clogging, power window motor failures, coolant leaks from intake manifold (V6 engines), noisy power steering pumps, alternator failures.
Preventative Maintenance:
Regularly inspect and change transmission fluid and filter, clean throttle body and EGR valve, check for coolant leaks, and listen for unusual noises.
📚 Vehicle History
Brand Heritage
Plymouth Legacy:
Plymouth was a brand of Chrysler Corporation known for offering value-oriented vehicles. The Voyager was its flagship minivan, a segment that transformed the automotive landscape.
Model Evolution
Generation Ns:
The 1996-2000 models represent the third generation of the Dodge Caravan/Plymouth Voyager. This generation introduced significant styling updates, improved safety features, and more refined powertrains compared to its predecessors.
Production
Manufacturing Locations:
Primarily assembled in St. Louis, Missouri, and Windsor, Ontario, Canada.
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Frequently appeared on Car and Driver's Ten Best list in its early years, solidifying the minivan's popularity.
Ratings
Consumer Reports:
Varied by year and specific engine/feature configuration. Generally considered a practical and versatile family vehicle, though some years/powertrains had reported reliability concerns addressed in the manual.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

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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