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

This Chrysler factory service-manual PDF set combines 1997 NS-platform information for Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager, and Chrysler Town & Country with GS international-market material for Chrysler Voyager and Grand Voyager. The GS VIN table identifies 1996 model-year coding, making this a 1996 GS and 1997 NS reference—not blanket 1996 coverage for every North American minivan. Its repair depth and reliance on hoists, pullers, presses, electrical test equipment, A/C service equipment, and DRB-family scan tools make it best suited to professional technicians and experienced owners with a properly equipped workshop.

• Engine repair coverage includes the 2.0L SOHC, 2.4L DOHC, 2.5L VM turbo diesel, 3.0L, 3.3L, and 3.8L engines, with removal, cylinder-head service, timing-system work, internal inspection, bearing fitting, oil-pump service, and engine-specific torque and wear specifications.

• Transmission and driveline sections cover the 31TH three-speed and 41TE four-speed automatic transaxles, A-598 five-speed manual transaxle, clutch assemblies, power transfer unit, front driveshafts, AWD rear driveline module, overrunning clutch, and viscous coupler.

• Brake, steering, and suspension repair spans base brakes, Teves Mark-20 ABS and traction control, hydraulic bleeding, DRB-assisted ABS service, wheel alignment, McPherson struts, control arms, power steering diagnosis, and FWD/AWD rear-suspension differences.

• Gasoline and diesel fuel-system procedures address fuel-pump modules, pressure testing, injectors, throttle-body controls, the Bosch VP36 diesel injection pump, high-pressure line testing, air bleeding, injection-pump timing, glow-plug controls, and turbocharger wastegate diagnosis.

• Body, HVAC, and electrical coverage includes doors, liftgate, glass, seats, trim, water-leak and wind-noise diagnosis, front and rear heater/A/C systems, refrigerant recovery and charging, actuator calibration, airbags, instruments, lighting, locks, windows, and the Body Control Module.

• A 454-page Group 8W wiring section supplies system schematics, circuit descriptions, connector pin-outs, splice data, component locations, ground locations, intermittent-fault checks, and factory wiring and terminal repair procedures.

Engine and Drivetrain Repair Depth

The engine chapters go well beyond routine maintenance. They document piston and cylinder-bore sizing, crankshaft and connecting-rod bearing selection, valve reconditioning, camshaft and crankshaft service, timing-belt or timing-chain installation, oil-pressure diagnosis, engine removal, and final mount adjustment. Separate procedures account for the mechanical differences among the four-cylinder, V6 gasoline, and VM diesel engines.

Transmission material includes hydraulic and clutch/servo pressure testing, road-test diagnosis, valve-body and clutch-pack reconditioning, differential repair, bearing adjustment, and complete internal disassembly. The 41TE section also covers DRB Quick Learn, pinion-factor setup, and torque-converter clutch break-in functions. A-598 procedures address synchronizers, input and intermediate shafts, shift-cable adjustment, and bearing preload.

Diagrams and Diagnostic Support

Representative drawings and schematics include 8W-10 Power Distribution, 8W-30 Fuel/Ignition Systems, 8W-31 Transmission Control System, 8W-43 Airbag System, 8W-80 Connector Pin-Outs, and the 2.5L diesel EGR vacuum-hose routing schematic. Component views, exploded assemblies, fastening sequences, diagnostic charts, hydraulic routing drawings, and engine-specific special-tool illustrations appear throughout the repair sections.

Special-tool references include Electrical Probe Package 6807, brake-bleeding equipment C-3496-B, 6920, and 6921, and diesel timing tools VM.1030, VM.1031, and VM.1032. Specification sections provide approved lubricants, maintenance schedules, fluid capacities, pressure-test data, electrical test values, clearances, wear limits, alignment data, and component-specific torque charts.

Important Scope and Service Cautions

The service manual contains system tests, troubleshooting charts, wiring diagnosis, and selected DRB functions, but some detailed fault-isolation routines refer to separate Chrysler Body or Powertrain Diagnostic Procedures manuals. Those diagnostic volumes are not included; the separate three-page Chrysler/Jeep/Dodge trouble-code reference in this package does not replace them.

The 2.0L SOHC is identified as a non-freewheeling engine, so timing-belt failure or incorrect valve timing can allow piston-to-valve contact. On the A-598 transaxle, shift forks and 1–2 synchronizer parts must not be interchanged with other assemblies or model years, and substituting unspecified sealant can damage the transaxle.

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.