Chrysler Voyager 2003-2007 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Codes Platform: Chrysler NS platform 👋 Introduction Market Position Segment: Minivan Competitive Analysis Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Pontiac Montana, Mercury Monterey Key Features Vehicle Type: Front-engine, Front-wheel-drive minivan Target Audience: Families, individuals requiring spacious and versatile transportation 📋 Manual Details Coverage Areas Years Covered: 2003, 2004, 2005, 2006, 2007 Page Count Estimated Pages: 2000-3000+ (typical for comprehensive workshop manuals) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain Chassis: Suspension, Steering, Brakes, Wheels & Tires Electrical: Ignition, Charging, Starting, Lighting, Instrumentation, Body Electrical, Powertrain Control Modules (PCM) Body: Interior, Exterior, HVAC, Safety Systems (Airbags, Seatbelts) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), circuit diagrams Repair: Component removal, installation, adjustment, overhaul procedures Technical Specifications: Torque values, clearances, electrical specifications, diagnostic parameters Technical Depth Depth: Comprehensive from basic maintenance to major component overhaul and electrical system diagnostics 📊 Manual Specifications File Format File Format: Searchable PDF, Printable Print Quality Quality: High-resolution, clear diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: EDZ (3.3L V6) Displacement: 3.3 Liters (203 cubic inches) Configuration: SOHC V6 Bore X Stroke: 3.44 in x 3.62 in (87.3 mm x 92.0 mm) Compression Ratio: 9.6:1 Horsepower: Approximately 180 hp @ 5000 rpm Torque: Approximately 205 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Fuel Tank Capacity: Approx. 18.0 gallons (68 L) Engine Variants Engine Code Optional: EGH (2.4L DOHC 4-cylinder - less common for this generation in US market) Engine Code Optional 2: VQ33E (3.3L V6 - Japanese market, potentially similar but check specific manual for regional variations) Cooling System Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (e.g., Mopar 50/50 Antifreeze/Coolant) Lubrication System Oil Type: SAE 5W-30 API Certified (refer to manual for specific viscosity grade recommendations based on ambient temperature) Oil Capacity: Approx. 4.5 quarts (4.3 L) with filter change Ignition System Spark Plugs: Refer to manual for OE or equivalent part numbers (e.g., Champion, NGK); typically platinum or iridium 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transaxle Transmission Model: Chrysler 41TE / 42LE (depending on engine/drivetrain configuration) Optional Transmission Type Optional: N/A for this generation/model in US market Features Shift Modes: Standard Drive, 1, 2, 3 (for engine braking or specific driving conditions) Fluid Specifications Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid Type 9602, MS-9602) or Mopar Genuine ATF+4 Fluid Capacity Transmission Fluid Capacity: Approx. 3.5 quarts (3.3 L) for dry fill, 7.5 quarts (7.1 L) total capacity 📐 Dimensions Exterior Length: Approx. 189.4 inches (4811 mm) Width: Approx. 72.0 inches (1829 mm) Height: Approx. 68.4 inches (1737 mm) Wheelbase: Approx. 119.3 inches (3030 mm) Interior Seating Capacity: 7 passengers (typically 2-2-3 configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 20.3 cubic feet (575 L) Cargo Volume With 3Rd Row Folded: Approx. 78.5 cubic feet (2223 L) Cargo Volume With 2Nd And 3Rd Rows Removed: Approx. 135.1 cubic feet (3825 L) Weights Curb Weight: Approx. 4000 - 4400 lbs (1814 - 2000 kg) depending on configuration Gross Vehicle Weight Rating Gvwr: Approx. 5750 lbs (2608 kg) Towing Capacity: Approx. 2000 lbs (907 kg) (check specific vehicle options for trailer tow package) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (2003-2007) NHTSA Front Impact Passenger: 4 Stars (2003-2007) NHTSA Side Impact Front Seat: 5 Stars (2003-2007) NHTSA Side Impact Rear Seat: 5 Stars (2003-2007) IIHS Roof Strength: Good (2007 model tested) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Passive Features Airbags: Frontal airbags for driver and front passenger, optional side curtain airbags Seatbelts: 3-point seat belts with pretensioners for front seats, lap/shoulder belts for second and third rows Child Seat Anchors: LATCH (Lower Anchors and Tethers for CHildren) system in second row 💡 Technology Features Infotainment Audio System: Optional AM/FM stereo with CD player, optional rear-seat entertainment system Navigation: Optional factory navigation system Driver Assistance Cruise Control: Standard cruise control Parking Sensors: Optional rear parking assist system Connectivity Power Outlets: 12V accessory power outlets Convenience Features Power Doors: Optional power sliding doors and power liftgate 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, or as indicated by the oil change indicator system (refer to manual for specific recommendation) Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed, check visually Spark Plug Replacement: Every 100,000 miles (160,000 km) for platinum/iridium plugs (check specific plug type) Transmission Fluid Change: Every 30,000 - 60,000 miles (48,000 - 96,000 km) or as...
Comprehensive from basic maintenance to major component overhaul and electrical system diagnostics
📊 Manual Specifications
File Format
File Format:
Searchable PDF, Printable
Print Quality
Quality:
High-resolution, clear diagrams and text
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EDZ (3.3L V6)
Displacement:
3.3 Liters (203 cubic inches)
Configuration:
SOHC V6
Bore X Stroke:
3.44 in x 3.62 in (87.3 mm x 92.0 mm)
Compression Ratio:
9.6:1
Horsepower:
Approximately 180 hp @ 5000 rpm
Torque:
Approximately 205 lb-ft @ 3600 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
Approx. 18.0 gallons (68 L)
Engine Variants
Engine Code Optional:
EGH (2.4L DOHC 4-cylinder - less common for this generation in US market)
Engine Code Optional 2:
VQ33E (3.3L V6 - Japanese market, potentially similar but check specific manual for regional variations)
Cooling System
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent (e.g., Mopar 50/50 Antifreeze/Coolant)
Lubrication System
Oil Type:
SAE 5W-30 API Certified (refer to manual for specific viscosity grade recommendations based on ambient temperature)
Oil Capacity:
Approx. 4.5 quarts (4.3 L) with filter change
Ignition System
Spark Plugs:
Refer to manual for OE or equivalent part numbers (e.g., Champion, NGK); typically platinum or iridium
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic Transaxle
Transmission Model:
Chrysler 41TE / 42LE (depending on engine/drivetrain configuration)
Optional
Transmission Type Optional:
N/A for this generation/model in US market
Features
Shift Modes:
Standard Drive, 1, 2, 3 (for engine braking or specific driving conditions)
Fluid Specifications
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid Type 9602, MS-9602) or Mopar Genuine ATF+4
Fluid Capacity
Transmission Fluid Capacity:
Approx. 3.5 quarts (3.3 L) for dry fill, 7.5 quarts (7.1 L) total capacity
📐 Dimensions
Exterior
Length:
Approx. 189.4 inches (4811 mm)
Width:
Approx. 72.0 inches (1829 mm)
Height:
Approx. 68.4 inches (1737 mm)
Wheelbase:
Approx. 119.3 inches (3030 mm)
Interior
Seating Capacity:
7 passengers (typically 2-2-3 configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.3 cubic feet (575 L)
Cargo Volume With 3Rd Row Folded:
Approx. 78.5 cubic feet (2223 L)
Cargo Volume With 2Nd And 3Rd Rows Removed:
Approx. 135.1 cubic feet (3825 L)
Weights
Curb Weight:
Approx. 4000 - 4400 lbs (1814 - 2000 kg) depending on configuration
Gross Vehicle Weight Rating Gvwr:
Approx. 5750 lbs (2608 kg)
Towing Capacity:
Approx. 2000 lbs (907 kg) (check specific vehicle options for trailer tow package)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (2003-2007)
NHTSA Front Impact Passenger:
4 Stars (2003-2007)
NHTSA Side Impact Front Seat:
5 Stars (2003-2007)
NHTSA Side Impact Rear Seat:
5 Stars (2003-2007)
IIHS Roof Strength:
Good (2007 model tested)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS)
Passive Features
Airbags:
Frontal airbags for driver and front passenger, optional side curtain airbags
Seatbelts:
3-point seat belts with pretensioners for front seats, lap/shoulder belts for second and third rows
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system in second row
💡 Technology Features
Infotainment
Audio System:
Optional AM/FM stereo with CD player, optional rear-seat entertainment system
Navigation:
Optional factory navigation system
Driver Assistance
Cruise Control:
Standard cruise control
Parking Sensors:
Optional rear parking assist system
Connectivity
Power Outlets:
12V accessory power outlets
Convenience Features
Power Doors:
Optional power sliding doors and power liftgate
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, or as indicated by the oil change indicator system (refer to manual for specific recommendation)
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed, check visually
Spark Plug Replacement:
Every 100,000 miles (160,000 km) for platinum/iridium plugs (check specific plug type)
Transmission Fluid Change:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or as specified by severe service conditions
Coolant Flush:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-4 years
Fluid Specifications
Brake Fluid Type:
DOT 3
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent ATF+4/Dexron III (verify in manual)
Windshield Washer Fluid:
Automotive windshield washer fluid, or equivalent with de-icing properties in cold climates
Known Issues
Common Problems:
Transmission issues (e.g., solenoid pack failure, torque converter shudder), CV joint wear, rear climate control leaks, power sliding door malfunctions, fuel pump failure, HVAC blower motor issues, engine oil leaks (e.g., valve cover gaskets)
📚 Vehicle History
Brand Heritage
Manufacturer History:
Chrysler Corporation, known for pioneering the minivan segment with the Dodge Caravan/Plymouth Voyager in the mid-1980s.
Model Evolution
Generation:
Third Generation (GS) - produced from 1996-2000, refreshed for 2001. This manual covers the later years of the GS generation with its facelift.
Production
Production Years:
1996-2007 (for the GS platform/facelift)
Assembly Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Automotive Journal Ratings:
Often praised for interior space and versatility, though sometimes criticized for ride quality and powertrain refinement compared to Japanese competitors.
Ratings
Fuel Economy Est City:
Approx. 16-19 MPG (depending on engine and configuration)
Fuel Economy Est Highway:
Approx. 22-25 MPG (depending on engine and configuration)
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