1988 Plymouth Voyager Repair Manual

The 1988 Plymouth Voyager is a front-wheel drive minivan featuring 2.2L and 2.5L four-cylinder engines, 3.0L V6 engine options, automatic and manual transmissions, power steering, front disc/rear drum brakes, and comprehensive electrical systems. This repair manual covers maintenance, troubleshooting, and repair procedures for all major components including engine, transmission, suspension, brakes, electrical, and body systems.

Vehicle Specifications

Key technical data for 1988 Plymouth Voyager models.

Maintenance Schedule

Recommended service intervals for optimal performance.

1. Oil and filter change: Every 3,000 miles or 3 months
2. Air filter replacement: Every 15,000 miles
3. Spark plugs: Every 30,000 miles
4. Timing belt: Every 60,000 miles (2.2L/2.5L engines)
5. Coolant flush: Every 30,000 miles or 2 years
6. Brake fluid: Every 30,000 miles or 2 years
7. Transmission fluid: Every 30,000 miles

WARNING! Always use jack stands when working under vehicle. Disconnect battery before electrical work.

Engine Repair

Procedures for engine maintenance and repair.

1. Compression test: Remove spark plugs, test each cylinder (125-150 psi normal)
2. Valve adjustment: Hydraulic lifters - no adjustment required
3. Timing belt replacement: Align marks, tension properly
4. Oil pump service: Replace if pressure below 10 psi at idle
5. Cylinder head removal: Torque bolts in sequence (70 ft-lbs)

CAUTION! Allow engine to cool completely before opening cooling system.

Transmission Service

• Automatic Transmission: A413 model, fluid type ATF+3
• Manual Transmission: A525 model, fluid type 75W-90 gear oil
• Fluid Capacity: Automatic: 7.5 quarts, Manual: 2.2 quarts
• Shift Linkage: Adjust for proper gear engagement
• Clutch: Hydraulic system, bleed if spongy pedal
• Differential: Integrated with transaxle

Brake System

Front disc brake pad replacement: Remove caliper, compress piston, install new pads. Rear drum brake service: Adjust shoes, check wheel cylinders. Master cylinder: Bench bleed before installation. Brake bleeding sequence: Right rear, left rear, right front, left front.

Brake Specifications: Front rotor minimum thickness: 0.810 inches, Rear drum maximum diameter: 9.030 inches.

Electrical System

Battery: Group 24, 12V 550 CCA. Alternator: 65-90 amp output. Starter: Direct drive type. Fuse panel: Under dashboard. Wiring diagrams: Color-coded for circuit identification.

1. Battery testing: Load test at 1/2 CCA rating
2. Charging system: 13.5-14.5 volts at 2000 RPM
3. Starter draw: 130-190 amps normal
4. Ground connections: Clean and tight at engine/body

Tip: Always disconnect battery negative terminal first when working on electrical system.

Suspension & Steering

Front suspension: MacPherson struts, lower control arms. Rear suspension: Twist-beam axle with coil springs. Steering: Rack and pinion, power assisted.

1. Strut replacement: Support vehicle, remove wheel, disconnect brake line bracket
2. Ball joints: Check for play, replace if worn
3. Tie rods: Adjust toe-in to 0° ± 0.25°
4. Wheel alignment: Camber: -0.5° to +0.5°, Caster: +1.5° to +2.5°
5. Power steering: Fluid type ATF+3, check for leaks at rack

WARNING! Use proper spring compressor when working with struts.

Cooling System

Radiator: Cross-flow design. Thermostat: 195°F opening temperature. Water pump: Gear-driven. Cooling fan: Electric with thermostatic control.

Fuel System

Fuel pump: In-tank electric, 13-15 psi pressure. Fuel filter: Replace every 30,000 miles. Injectors: Bosch design, clean every 60,000 miles. Throttle body: Clean with appropriate cleaner.

CAUTION! Relieve fuel pressure before disconnecting fuel lines.

Troubleshooting Guide

Technical Support: Chrysler Technical Service Bulletins available for common issues.

Parts Source: Genuine Mopar parts recommended for optimal performance.