Plymouth Voyager & Grand Voyager 1996–2000 Service Manual Set (P/N 81-370-0005)

The diagnostic volumes provide fault-isolation charts, while the corresponding service sections supply mechanical removal, repair and installation procedures. Match the publication to the vehicle’s year, market and powertrain before selecting a test or repair procedure.

Year coverage: The 1996–1997 folder contains a 1997-titled electronic service manual. There is no standalone 1999 service manual, so buyers should not assume a continuous five-year run of year-specific publications.

ABS diagnostics: Certain ABS warning-lamp faults refer to a separate anti-lock brake diagnostic manual, which is not included as a standalone volume.

Text Search, Bookmarks and Wiring Detail

Search and diagram navigation: Service chapters and diagnostic text support PDF text search, but some diagram lettering is outside the searchable text layer; the 2000 wiring PDF is only partly searchable. Most service files and the gasoline diagnostic volume have embedded bookmarks; the body and VM diesel diagnostic volumes do not. Small pin numbers and wire codes require zooming, and some body-diagnostic circuit labels are faint.

The ZIP download contains 191 printable PDFs totaling 8,021 pages. This includes 10 front-matter and navigation pages, the separate three-page trouble-code list, and blank pages within the files.

Engine Repair, Transaxle Service and Electrical Fault Tracing

These are selected content highlights, rather than a complete table of contents. Other included topics range from compass calibration to memory-seat soft-stop resetting.

• Engine repair: Step-by-step engine removal and installation, cylinder-head and timing-system work, and internal inspection for gasoline and VM turbo-diesel applications.

• Fuel, cooling and emissions: Maintenance schedules, lubrication and cooling-system service, fuel-delivery tests, exhaust repairs and emission-control diagnosis.

• Transaxles and driveline: 31TH and 41TE automatic transaxles, A-598/A-558 manual-transaxle procedures, clutch repair, AWD power-transfer units, driveshafts and CV joints.

• Brakes and chassis: Suspension diagnosis, base and anti-lock brake service, hydraulic bleeding, steering-system work, wheels and tires.

• Body and HVAC: Frame and bumpers, doors and glass, passive restraints, and front/rear HVAC testing, component replacement and adjustment.

• Factory diagnostics: DRB/DRB III fault isolation for gasoline and VM diesel powertrains, BCM and CCD bus faults, SKIS/VTSS and body electrical systems.

• Wiring references: Three 8W electrical sections with power and ground distribution, splice information, connector pin-outs, and connector/ground location views.

The service material was prepared for professional automotive technicians involved in daily repair work; the specified diagnostic procedures require DRB/DRB III access and appropriate electrical test equipment.

Powertrain and Market Differences

VIN and body-code tables distinguish Voyager and Grand Voyager series, short- and long-wheelbase bodies, FWD/AWD layouts, and market-specific LHD/RHD equipment. These distinctions help match the vehicle to the appropriate diagrams and service procedures.

North American sections address 2.4L, 3.0L, 3.3L and 3.8L gasoline engines; the 2000 material also identifies the 3.3L flexible-fuel configuration. International sections add the 2.0L gasoline and 2.5L VM turbo-diesel engines.

Trim and price-class references include Voyager/Grand Voyager SE and LE, Voyager LX, and low-line, high-line, premium, sport and special configurations.

Automatic and Manual Transaxle Repair Depth

Automatic-transaxle coverage extends to internal disassembly and reassembly, valve-body and clutch work, hydraulic pressure testing, adjustments and final checks. Manual-transaxle sections include differential and synchronizer work, bearing adjustment and crossover-cable adjustment, with separate A-558 removal procedures for RHD vehicles.

The A-598 section warns that incorrect lubricant can cause hard shifting and bearing, gear or synchronizer failure.

Body, Powertrain and CCD Bus Diagnosis

The body diagnostic volume supplies 16 airbag test paths covering squib opens and shorts, shorts to power or ground, warning-lamp faults, lost CCD communication, stored codes and Airbag Control Module replacement.

Vehicle Communication charts isolate no-response faults from the ACM, BCM, instrument cluster, PCM, TCM, ABS controller and HVAC module, together with bus shorts, opens, missing termination and bias faults. This provides a diagnostic path for distinguishing communication failures from faults within an individual system.

Gasoline and VM diesel volumes add DTC charts, no-start and drivability tests, sensor calibration checks, fuel-delivery diagnosis, SKIS programming and repair-verification routines.

Body-system tests also address remote keyless entry, instruments, lighting, power locks, folding mirrors, audio, and front/rear wipers. The Body Diagnostic Procedures volume covers base, midline and highline body control modules, with LHD/RHD location differences.

Wiring Diagrams, Tools and Service Data

Named electrical references include Airbag System, Transmission Control System, Body Control Module, Anti-Lock Brakes, Power Door Locks and Wipers diagrams. Component indexes, connector cavity assignments, splice charts and physical location illustrations support circuit tracing.

Wiring and terminal repair sections identify probing package 6807, probing tool 6801, connector tool 6742, terminal kit 6680 and Augat terminal tool 6932.

The wiring instructions warn that replacing an original plastic harness clip with a metal fastener, or drilling in the restricted front strut-tower area, can damage the coil-spring coating and lead to corrosion failure.

Specifications accompany the applicable repair sections: torque tables, capacities and approved fluids, pressure-test data, electrical values, wear limits, clearances, adjustments and calibration references.

Supplemental-restraint diagnosis requires strict factory handling procedures because improper testing can cause component damage or accidental deployment.

A-598 Ratio and Fill-Capacity Examples

For international A-598 applications, the gearing tables list a 3.69 first-gear ratio and 4.08 final drive for the 2.0L gasoline engine. The 2.4L gasoline and 2.5L turbo-diesel applications use a 3.36 first-gear ratio and 3.88 final drive.

The NV T750 (A-598/A-558) specification table lists a fluid-fill capacity of 1.9–2.2 liters (2.0–2.3 U.S. quarts), alongside component-specific torque specifications.