Chrysler Voyager SE, LE & LX Repair Manual (1997–1998)

This Chrysler factory service manual for Voyager and Grand Voyager combines 1997 NS base chapters with 1998 NS/GS material for SE, LE, and LX applications. The NS base chapters include the 3.0L V6. The NS/GS sections identify short- and long-wheelbase configurations and the commercial van, with right-hand-drive procedures where the hardware differs.

PDF Text Search and Wiring Detail

Search and bookmarks: The main text is searchable, and embedded bookmarks lead to service groups and individual procedures. Some illustration labels are part of the artwork. Zoom in to read small wire codes, connector IDs, and pin numbers.

The download is one printable English-language PDF with 1,936 pages, including the Group Tab Locator and 50 blank pages.

Engine Overhaul, Transaxle Tests, and Chassis Service

This selection of workshop procedures highlights the main repair areas. The manual also includes battery load testing and clutch pedal position switch service.

• Engine repair: Step-by-step procedures cover engine removal, cylinder-head and valve work, timing systems, crankshaft and bearing service, and piston and liner inspection.
• VM diesel fuel system: Bosch VP36 pump timing, injector and sensor tests, fuel filter and water separator service, glow plugs and relay, high-pressure lines, and fuel-system bleeding.
• Transaxles and AWD: 31TH and 41TE automatic transaxle service, A-598 disassembly and bearing adjustment, A-558 removal and shift controls for right-hand-drive vehicles, and power transfer unit service.
• Suspension and brakes: MacPherson struts, the suspension cradle, control arms, hubs and bearings, wheel alignment, and FWD and AWD rear leaf springs. Brake procedures cover bleeding, proportioning-valve tests, and rotor and drum machining.
• Body and climate control: Front and sliding door service, latches, glass, seats, restraints, and water-leak and wind-noise diagnosis. Front and rear HVAC coverage includes actuator calibration, leak testing, evacuation, and R-134a charging.
• Electrical troubleshooting: Group 8W includes gas and diesel fuel-system diagrams, transmission control wiring, connector pin-outs, and splice and ground locations for tracing circuit faults.

The manual suits automotive technicians familiar with scan-tool diagnosis, component measurement, and service work that requires dedicated pullers and fixtures.

Diesel Mechanical and Fuel Service

The VM diesel section covers valve and seat inspection, camshaft and crankshaft work, removable cylinder liners, lubrication, cooling, and emissions controls. The fuel section explains the accelerator input, instrumented No. 1 injector, fuel return circuits, air-in-fuel checks, and turbocharger wastegate. Chrysler specifies replacement of the Bosch pump as an assembly when it requires internal service.

Workshop references include the Cooling System Operation – 2.5L VM Diesel and Engine Lubrication System – SOHC diagrams. Diesel tooling includes pulley and gear remover VM.1000A, liner protrusion tool VM.1010, injector socket VM.1012A, and engine support brackets VM.1026.

Transaxle Diagnosis and AWD Repair Limits

For a slipping 41TE, the road-test chart links selector positions to the clutches in use. The hydraulic schematics and pressure tests help narrow down which circuit needs further checks before teardown. The section also covers clutch air checks, cooler flushing, pump volume, solenoid and valve-body service, input-clutch repair, differential preload, Quick Learn, and Electronic Pinion Factor. Detailed fault-code diagnosis requires the separate Powertrain Diagnostic Test Procedure Manual.

The AWD power transfer unit section covers leak diagnosis and service of seals, gaskets, the end-cover ball bearing, and the output flange. Chrysler calls for unit replacement if the ring gear, pinion, or tapered roller bearings fail.

Brake and Suspension References

The All Wheel Drive Rear Suspension view and the non-ABS brake tube routing diagram help identify parts and line locations. The manual also covers rear load-leveling shocks, parking-brake adjustment, and Teves Mark 20 ABS. Detailed electronic ABS diagnosis requires the separate Teves manual. Service tools include ball-joint tools 6758 and 6919, tie-rod-end remover MB-991113, brake pressure test fittings 6833, and gauge set C-4007-A.

The wrong lubricant can damage A-598 bearings, gears, or synchronizers. Hammering a wheel stud out of the hub flange can damage the hub bearing. High-pressure diesel fuel can penetrate skin, and under-vehicle work requires secure support at the specified lift points.

VM Diesel Liner and Injector Specifications at a Glance

The cylinder-liner section specifies 0.01–0.06 mm of liner protrusion above the block deck on the 2.5L VM diesel. The manual uses that range to determine the correct liner shim thickness.

For the same engine, the injector bench test specifies an opening pressure of 15,000–15,800 kPa (2,175–2,291 psi).