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Chrysler Grand Voyager 2001 Service Repair Manual

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Basic Information Identification Make: Chrysler Model: Grand Voyager Year: 2001 Codes Chassis Code: NS/GS (1996-2007, with facelifts) Engine Codes Common: EGW (2.4L), EGK (3.3L), EGG (3.8L) Introduction Market Position Vehicle Segment: Full-size Minivan Target Audience: Families, people requiring versatile passenger and cargo space. Competitive Analysis Key Competitors 2001: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, GMC Safari, Oldsmobile Silhouette. Key Features Versatility: Flexible seating arrangements (e.g., Stow 'n Go precursors, removable seats), ample cargo capacity. Powertrain Options: V6 engine options offering a balance of power and refinement for hauling. Comfort And Convenience: Designed for long-distance comfort, often featuring dual-zone climate control and entertainment options. Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair for all vehicle systems. Page Count Estimated Page Count: Over 1500 pages (typical for a full service manual of this era) Manual Type Manual Classification: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Delivery Format: PDF Download Manual Coverage Systems Covered Engine System: Engine mechanical, cooling, lubrication, fuel, ignition, emission controls, engine diagnostics. Transmission System: Automatic transmission service, removal, installation, overhaul, fluid specifications, shift control. Drivetrain System: Front-wheel drive, axle shafts, CV joints, differential service. Suspension System: Front and rear suspension components, steering system, alignment specifications. Brake System: Front and rear brakes (disc/drum), ABS, hydraulic system, parking brake. Electrical System: Battery, charging system, starting system, lighting, instruments, body electrical, power accessories. HVAC System: Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair. Body And Frame: Body panels, interior trim, doors, glass, bumpers, structural components, rust repair. Restraint Systems: Airbag system (SRS) diagnosis and service, seat belts. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid top-offs, tune-ups, spark plug replacement, belt inspection/replacement. Diagnostic Procedures: Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic codes and interpretation. Repair Procedures: Component removal, installation, and overhaul for all major systems. Overhaul Procedures: Detailed engine and transmission rebuild procedures. Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits. Technical Depth Diagnostics Level: Advanced diagnostics, including use of scan tools and specific test procedures. Repair Detail: Step-by-step instructions with torque specifications and special tool requirements. Troubleshooting Methodology: Systematic approach to identifying and resolving common and uncommon faults. Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality: High-resolution, printable pages replicating original manual quality. Binding Type Digital Binding: N/A (Digital Format) Paper Type Digital Paper Type: N/A (Digital Format) Engine Specifications Primary Engine Engine Type 3.3L: 3.3L (201ci) OHV V6 (3 Valve) Engine Code 3.3L: EGK Horsepower 3.3L: Approx. 170-180 hp @ 4700-5000 rpm Torque 3.3L: Approx. 200-210 lb-ft @ 3500-4000 rpm Optional Engine Engine Type 3.8L: 3.8L (230ci) OHV V6 (3 Valve) Engine Code 3.8L: EGG Horsepower 3.8L: Approx. 190-200 hp @ 4400-4700 rpm Torque 3.8L: Approx. 230-240 lb-ft @ 3200-3500 rpm Engine Type 2.4L: 2.4L (148ci) DOHC Inline 4-cylinder (VVT) Engine Code 2.4L: EGW Horsepower 2.4L: Approx. 150 hp @ 5200 rpm Torque 2.4L: Approx. 165 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline, 87 octane recommended (91 for optimal performance in some cases) Emission Control: Catalytic converter, EGR (Exhaust Gas Recirculation), Oxygen sensors. Transmission Standard Transmission Type V6: 4-speed Automatic Transaxle Transmission Code V6: 41TE, 42LE Transmission Type I4: 4-speed Automatic Transaxle Transmission Code I4: 41AE Features Transmission Control: Electronic control, Torque converter lock-up. Fluid Type: ATF+4 (Automatic Transmission Fluid type 4) Fluid Capacity: Approx. 4.5-5.5 quarts (initial fill/drain and fill, varies) Dimensions Exterior Length: Approx. 199.5 inches Width: Approx. 76.7 inches Height: Approx. 67.4 inches Wheelbase: Approx. 119.3 inches Cargo Cargo Volume Behind 3Rd Row: Approx. 30-35 cubic feet Cargo Volume Behind 2Nd Row: Approx. 70-80 cubic feet Cargo Volume Max: Approx. 140-160 cubic feet (with rear seats removed) Weights Curb Weight: Approx. 4200-4600 lbs (depending on engine and configuration) Gross Vehicle Weight Rating Gvwr: Approx. 5800 lbs Safety Features Ratings NHTSA Frontal Impact Driver 2001: 5 Stars NHTSA Frontal Impact Passenger 2001: 5 Stars NHTSA Side Impact Front Seat 2001: 4 Stars NHTSA Side Impact Rear Seat 2001: 4 Stars Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front side-impact airbags Seat Belts: 3-point seat belts for all occupants, driver/passenger pretensioners. Child Safety: LATCH (Lower Anchors and Tethers for Children) system, rear door child safety locks. Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette and CD player, optional premium sound systems, rear seat entertainment options. Navigation: Optional factory navigation system. Driver Assistance Cruise Control: Standard cruise control. Parking Assist: Optional rear park assist sensors. Connectivity Remote Keyless Entry: Standard or optional remote keyless entry system. Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6 months, depending on oil type (conventional vs. synthetic)...
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Chrysler Grand Voyager 2001 Service Repair Manual
Basic Information
Identification
Make: Chrysler
Model: Grand Voyager
Year: 2001
Codes
Chassis Code: NS/GS (1996-2007, with facelifts)
Engine Codes Common: EGW (2.4L), EGK (3.3L), EGG (3.8L)
Introduction
Market Position
Vehicle Segment: Full-size Minivan
Target Audience: Families, people requiring versatile passenger and cargo space.
Competitive Analysis
Key Competitors 2001: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, GMC Safari, Oldsmobile Silhouette.
Key Features
Versatility: Flexible seating arrangements (e.g., Stow 'n Go precursors, removable seats), ample cargo capacity.
Powertrain Options: V6 engine options offering a balance of power and refinement for hauling.
Comfort And Convenience: Designed for long-distance comfort, often featuring dual-zone climate control and entertainment options.
Manual Details
Coverage Areas
Manual Coverage Scope: Comprehensive service and repair for all vehicle systems.
Page Count
Estimated Page Count: Over 1500 pages (typical for a full service manual of this era)
Manual Type
Manual Classification: Factory Service Manual (FSM) / Repair Manual
Language
Language: English
Format
Delivery Format: PDF Download
Manual Coverage
Systems Covered
Engine System: Engine mechanical, cooling, lubrication, fuel, ignition, emission controls, engine diagnostics.
Transmission System: Automatic transmission service, removal, installation, overhaul, fluid specifications, shift control.
Drivetrain System: Front-wheel drive, axle shafts, CV joints, differential service.
Suspension System: Front and rear suspension components, steering system, alignment specifications.
Brake System: Front and rear brakes (disc/drum), ABS, hydraulic system, parking brake.
Electrical System: Battery, charging system, starting system, lighting, instruments, body electrical, power accessories.
HVAC System: Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair.
Body And Frame: Body panels, interior trim, doors, glass, bumpers, structural components, rust repair.
Restraint Systems: Airbag system (SRS) diagnosis and service, seat belts.
Procedures Included
Maintenance Procedures: Oil changes, filter replacements, fluid top-offs, tune-ups, spark plug replacement, belt inspection/replacement.
Diagnostic Procedures: Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic codes and interpretation.
Repair Procedures: Component removal, installation, and overhaul for all major systems.
Overhaul Procedures: Detailed engine and transmission rebuild procedures.
Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits.
Technical Depth
Diagnostics Level: Advanced diagnostics, including use of scan tools and specific test procedures.
Repair Detail: Step-by-step instructions with torque specifications and special tool requirements.
Troubleshooting Methodology: Systematic approach to identifying and resolving common and uncommon faults.
Manual Specifications
File Format
File Type: PDF
Searchability: Searchable text content for quick information retrieval.
Print Quality: High-resolution, printable pages replicating original manual quality.
Binding Type
Digital Binding: N/A (Digital Format)
Paper Type
Digital Paper Type: N/A (Digital Format)
Engine Specifications
Primary Engine
Engine Type 3.3L: 3.3L (201ci) OHV V6 (3 Valve)
Engine Code 3.3L: EGK
Horsepower 3.3L: Approx. 170-180 hp @ 4700-5000 rpm
Torque 3.3L: Approx. 200-210 lb-ft @ 3500-4000 rpm
Optional Engine
Engine Type 3.8L: 3.8L (230ci) OHV V6 (3 Valve)
Engine Code 3.8L: EGG
Horsepower 3.8L: Approx. 190-200 hp @ 4400-4700 rpm
Torque 3.8L: Approx. 230-240 lb-ft @ 3200-3500 rpm
Engine Type 2.4L: 2.4L (148ci) DOHC Inline 4-cylinder (VVT)
Engine Code 2.4L: EGW
Horsepower 2.4L: Approx. 150 hp @ 5200 rpm
Torque 2.4L: Approx. 165 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI)
Fuel Type: Unleaded gasoline, 87 octane recommended (91 for optimal performance in some cases)
Emission Control: Catalytic converter, EGR (Exhaust Gas Recirculation), Oxygen sensors.
Transmission
Standard
Transmission Type V6: 4-speed Automatic Transaxle
Transmission Code V6: 41TE, 42LE
Transmission Type I4: 4-speed Automatic Transaxle
Transmission Code I4: 41AE
Features
Transmission Control: Electronic control, Torque converter lock-up.
Fluid Type: ATF+4 (Automatic Transmission Fluid type 4)
Fluid Capacity: Approx. 4.5-5.5 quarts (initial fill/drain and fill, varies)
Dimensions
Exterior
Length: Approx. 199.5 inches
Width: Approx. 76.7 inches
Height: Approx. 67.4 inches
Wheelbase: Approx. 119.3 inches
Cargo
Cargo Volume Behind 3Rd Row: Approx. 30-35 cubic feet
Cargo Volume Behind 2Nd Row: Approx. 70-80 cubic feet
Cargo Volume Max: Approx. 140-160 cubic feet (with rear seats removed)
Weights
Curb Weight: Approx. 4200-4600 lbs (depending on engine and configuration)
Gross Vehicle Weight Rating Gvwr: Approx. 5800 lbs
Safety Features
Ratings
NHTSA Frontal Impact Driver 2001: 5 Stars
NHTSA Frontal Impact Passenger 2001: 5 Stars
NHTSA Side Impact Front Seat 2001: 4 Stars
NHTSA Side Impact Rear Seat 2001: 4 Stars
Active Features
ABS: Standard Anti-lock Braking System (ABS)
Traction Control: Optional Traction Control System (TCS)
Passive Features
Airbags Front: Driver and front passenger airbags
Airbags Side: Optional front side-impact airbags
Seat Belts: 3-point seat belts for all occupants, driver/passenger pretensioners.
Child Safety: LATCH (Lower Anchors and Tethers for Children) system, rear door child safety locks.
Technology Features
Infotainment
Audio System: Factory AM/FM stereo with cassette and CD player, optional premium sound systems, rear seat entertainment options.
Navigation: Optional factory navigation system.
Driver Assistance
Cruise Control: Standard cruise control.
Parking Assist: Optional rear park assist sensors.
Connectivity
Remote Keyless Entry: Standard or optional remote keyless entry system.
Maintenance
Service Intervals
Oil Change Interval: Every 3,000-7,500 miles or 6 months, depending on oil type (conventional vs. synthetic) and driving conditions (refer to manual for specifics).
Air Filter Replacement: Every 15,000-30,000 miles or as needed based on inspection.
Spark Plug Replacement V6: Approx. 60,000-100,000 miles (depending on plug type, e.g., platinum or iridium).
Transmission Fluid Change: Every 30,000-60,000 miles or as per severe service recommendations.
Fluid Specifications
Engine Oil Grade: API Certified SAE 5W-30 or 10W-30 (check manual for climate-specific recommendations and engine type).
Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) Orange Coolant, or equivalent (50/50 mix with distilled water).
Brake Fluid Type: DOT 3 or DOT 4 (refer to cap or manual for exact specification).
Known Issues
Transmission Problems: Torque converter shudder, internal seal wear, solenoid issues in older 41TE/42LE transmissions.
Engine Mounts: Premature wear of engine and transmission mounts leading to vibration.
Rear Strut Mounts: Failure of rear strut mounts and bearings.
Power Sliding Doors: Issues with motors, latches, and cables on optional power sliding doors.
Wiper Motor: Failure of the front wiper motor.
Window Regulators: Failure of power window regulators.
Vehicle History
Brand Heritage
Chrysler Minivan Pioneer: Chrysler is widely credited with inventing the modern minivan segment with the Dodge Caravan/Plymouth Voyager in 1984. The Grand Voyager is an extended wheelbase version.
Model Evolution
Generation For 2001: Second Generation (NS/GS), launched in 1996, with a significant facelift for the 2001 model year (sometimes referred to as 2.5 generation).
Facelift 2001 Updates: Revised front and rear styling, updated interior, introduction of the 2.4L DOHC engine, improved safety features.
Production
Assembly Locations: Windsor, Ontario, Canada; St. Louis, Missouri, USA (for some markets/variants)
Global Name: Known as Chrysler Voyager and Chrysler Grand Voyager in many markets outside North America, and as Dodge Grand Caravan in North America.
Awards & Recognition
Recognitions
Car And Driver 10Best: Chrysler minivans (including the Grand Voyager platform) were frequent recipients of Car and Driver's '10Best' list in earlier generations, establishing their benchmark status.
Consumer Reports Ratings: Consumer Reports ratings for this generation were often mixed, with praise for practicality but concerns regarding long-term reliability in certain areas (e.g., powertrain).
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