Plymouth Voyager 1996–1997 Service Manual Set (P/N 81-370-7105)

The factory chapters provide repair procedures and system tests. The separate code reference supplies definitions; it does not replace the vehicle-specific diagnostic procedures.

The GS identification table uses 1996 model-year coding. This package should not be treated as blanket 1996 coverage for every North American NS minivan. Some detailed fault-isolation and instrument-calibration routines require separate Chrysler Body or Powertrain Diagnostic Procedures manuals, which are not included.

Searchable PDFs and Chapter Navigation

Text search and diagram detail: All 61 PDFs contain searchable text. Most chapter files have embedded bookmarks; the speed-control chapter, navigation files, and code reference do not. The instrument-panel supplement has a short outline, and one chime-supplement bookmark has no usable destination. Small wiring and connector labels remain readable when enlarged.

One ZIP contains 61 printable PDFs totaling 2,267 pages. This total includes two navigation pages, 43 blank/divider pages elsewhere in the manual, and 342 pages of separately supplied international supplements, including eight blank pages. Those supplements repeat material already present in the combined chapter files.

Powertrain, Chassis, and Electrical Service

The following selected coverage highlights are not a complete contents list. Further topics include immobilizer operation and compass calibration.

• Engine repair: Step-by-step procedures for engine removal, cylinder-head service, timing-system work, internal inspection, bearing fitting, and oil-pump service across gasoline and VM diesel configurations.

• Transmissions and AWD: 31TH and 41TE automatic transaxle diagnosis and overhaul, A-598 manual transaxle repair, clutch service, power transfer unit, rear driveline module, overrunning clutch, and viscous coupler.

• Brakes, steering, and suspension: Base brakes, Teves Mark-20 ABS and traction control, hydraulic bleeding, DRB-assisted service, wheel alignment, McPherson struts, control arms, and FWD/AWD rear-suspension differences.

• Gasoline and diesel fuel systems: Fuel-pump modules, pressure testing, injectors, throttle-body controls, Bosch VP36 injection-pump timing, high-pressure line testing, air bleeding, and glow-plug controls.

• Electrical diagnosis: Battery, starter, charging, and ignition tests, plus instruments, airbags, lighting, locks, windows, Body Control Module circuits, and system-specific wiring diagrams.

• Body and climate control: Doors, liftgate, glass, seats, trim, water-leak and wind-noise diagnosis, front and rear heater/A/C systems, refrigerant recovery and charging, and actuator calibration.

• Maintenance and cooling: Gasoline and diesel service schedules, lubricant specifications, fluid-capacity tables, cooling-system leak tests, thermostat and water-pump service, and accessory-belt adjustment.

The repair depth and use of hoists, presses, electrical test equipment, A/C service equipment, and DRB-family scan tools suit technicians and experienced owners with an equipped workshop.

Engine and Transaxle Repair Depth

Piston and cylinder-bore sizing tables, crankshaft and connecting-rod bearing selection data, and wear specifications support measurement-based parts selection during overhaul. The engine chapters also cover valve reconditioning, camshaft and crankshaft service, timing-belt or timing-chain installation, oil-pressure diagnosis, and final engine-mount adjustment.

The 2.0L SOHC engine has a non-freewheeling valve train: timing-belt failure can cause piston-to-valve contact.

Automatic-transaxle material extends to hydraulic and clutch/servo pressure tests, valve-body and clutch-pack reconditioning, differential repair, and bearing adjustment. The 41TE procedures include DRB Quick Learn, pinion-factor setup, and torque-converter clutch break-in functions.

A-598 instructions address synchronizers, input and intermediate shafts, shift-cable adjustment, and bearing preload. Its service cautions cover restrictions on interchanging shift forks and 1–2 synchronizer components, including parts from earlier model years, and warn that substitute sealants can damage the transaxle.

Fuel-System and Emissions Testing

Diesel performance checks distinguish air in the fuel supply and high-pressure line leakage from injector faults. The related sections cover fuel-shutdown controls and glow-plug testing, while emissions material addresses EGR operation, vacuum routing, evaporative controls, and PCV testing.

Use the designated lifting points and rated support equipment. Fuel pressure must be relieved before opening gasoline or diesel lines, and the R-134a system requires approved refrigerant recovery equipment.

Wiring Diagrams and Factory Test Equipment

The Group 8W section contains system schematics, circuit descriptions, connector pin-outs, splice data, component and ground locations, intermittent-fault checks, and wiring and terminal repair procedures.

Examples include 8W-10 Power Distribution, 8W-30 Fuel/Ignition Systems, and 8W-31 Transmission Control System. Restraint and terminal identification are illustrated in 8W-43 Airbag System and 8W-80 Connector Pin-Outs; the diesel emissions material includes an EGR vacuum-hose routing schematic.

Component views, exploded assemblies, fastening sequences, diagnostic charts, hydraulic routing drawings, and special-tool illustrations support the repair sections. Tool references include Probe Package 6807, brake-bleeding tools C-3496-B, 6920, and 6921, and diesel timing tools VM.1030, VM.1031, and VM.1032.

Crankshaft and Final-Drive Specification Samples

For the 2.0L SOHC engine, the crankshaft specification lists end play of 0.09–0.24 mm. The engine chapter describes both dial-indicator and feeler-gauge checking methods.

A-598 data distinguishes a 3.88 final-drive ratio for the 2.4L gasoline and 2.5L turbo-diesel applications from 4.08 for the 2.0L gasoline application.