1996–2000 Plymouth Voyager SE, LX, Grand SE, and Grand LX Service Manual (P/N 80B5D30A060)

This factory PDF set brings together 1996-1997, 1998, and 2000 NS/GS minivan service information, including North American and international-market material. It is best suited to professional technicians and experienced owners who can interpret factory wiring diagrams, use a DRB/DRB III and high-impedance test equipment, and follow vehicle-specific safety and special-tool requirements.

• Covers Plymouth Voyager and Grand Voyager applications plus the related Dodge Caravan/Grand Caravan and Chrysler Town & Country models identified in the factory files, with FWD/AWD, short- and long-wheelbase, LHD/RHD, and market-specific configurations.
• Engine sections document gasoline and turbo-diesel diagnosis and repair, including removal and installation, cylinder-head and timing-system work, internal inspection, lubrication, cooling, fuel delivery, exhaust, and emission controls.
• Drivetrain material includes 31TH and 41TE automatic transaxles, the A-598 manual transaxle and clutch, power-transfer-unit/AWD systems, driveshafts and CV joints, internal disassembly and reassembly, hydraulic testing, adjustments, and final checks.
• Chassis and body chapters cover suspension, base and anti-lock brakes, steering, wheels and tires, frame and bumpers, doors and glass, passive restraints, and HVAC testing, component replacement, and adjustment.
• Dedicated DRB/DRB III diagnostic volumes trace gasoline and VM diesel powertrain faults, BCM and CCD bus failures, SKIS/VTSS, airbags, remote keyless entry, instruments, lighting, power locks, folding mirrors, audio, and front/rear wiper systems.
• Three large 8W electrical sections provide wiring diagrams, power and ground distribution, splice information, connector pin-outs, and connector/ground location views across the powertrain, chassis, and body systems.
• The download contains 8,021 PDF pages in 191 PDF files: 2,264 pages for 1996-1997, 1,994 pages for 1998, 3,760 pages for 2000, and a separate 3-page Chrysler/Jeep/Dodge trouble-code list. The 2000 factory service material identifies Publication No. 81-370-0005.

Year, Powertrain, and Market Coverage

VIN and body-code tables distinguish Voyager and Grand Voyager series, short- and long-wheelbase bodies, FWD and AWD, and regional equipment. The files address 2.4L, 3.0L, 3.3L, and 3.8L gasoline engines; 2000 material also identifies the 3.3L flexible-fuel configuration. International sections add the 2.0L gasoline and 2.5L VM turbo-diesel engines, A-598 five-speed manual transaxle, clutch, and market-specific LHD/RHD systems. Trim and price-class references include Voyager/Grand Voyager SE and LE, Voyager LX, and low-line, high-line, premium, sport, and special configurations.

This is not a continuous five-year run: the archive contains factory material for 1996-1997, 1998, and 2000, but no standalone 1999 service manual. Buyers working on a 1999 vehicle should not assume model-year-specific coverage from this set.

Factory Diagnostic Depth

The 2000 material adds a 690-page Body Diagnostic Procedures volume, a 436-page 2.5L VM diesel diagnostic volume, and a 364-page gasoline powertrain diagnostic volume. The body volume supplies 16 airbag test paths for squib opens, 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. Gasoline and diesel books add DTC charts, no-start and drivability tests, sensor calibration checks, fuel-delivery diagnosis, SKIS programming, and repair-verification routines.

Wiring, 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 call out probing package 6807, probing tool 6801, connector tool 6742, terminal kit 6680, and Augat terminal tool 6932.

Specifications are integrated with the applicable repair sections and include torque tables, capacities and approved fluids, pressure-test data, electrical values, wear limits, clearances, adjustments, and calibration references. The A-598 section warns that incorrect lubricant can cause hard shifting and bearing, gear, or synchronizer failure. The wiring chapters also warn that substituting a metal fastener for the original plastic harness clip, or drilling in the restricted front strut-tower area, can damage the spring coating and lead to corrosion failure.

Supplemental-restraint diagnosis requires strict factory handling procedures because improper testing can cause component damage or accidental deployment. The Body Diagnostic Procedures volume is a fault-isolation manual; when mechanical removal or repair is required, it directs the reader to the matching service-manual section included elsewhere in the set. Certain ABS warning-lamp faults refer to a separately titled anti-lock brake diagnostic manual, which is not included as a standalone volume.