Chrysler Grand Voyager 2005-2007 Service Repair Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Grand Voyager Years Covered: 2005, 2006, 2007 Codes Chassis Code: RT Body Style 👋 Introduction Market Position Vehicle Segment: Full-size Minivan Target Audience: Families, individuals requiring significant passenger and cargo capacity, fleet operators. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Freestar/Mercury Monterey, Nissan Quest, Kia Sedona, Hyundai Entourage. Key Features Interior Versatility: Flexible seating arrangements (Stow 'n Go or similar systems), ample passenger space, family-friendly features. Powertrain Options: Focus on V6 engines for towing and hauling capability. Comfort And Convenience: Features like power sliding doors, power liftgate, rear-seat entertainment options. 📋 Manual Details Coverage Areas Primary Coverage: North America (US, Canada, Mexico) Secondary Coverage: Export Markets (where applicable for RT platform) Page Count Estimated Pages: 1500-2000 (typical for comprehensive workshop manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Digital (likely PDF, sometimes CD-ROM) 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System Drivetrain: Automatic Transmission (e.g., 4-speed, 6-speed variants), Driveline Components, Axles, Driveshafts Chassis: Suspension (Front and Rear), Steering System, Brake System (ABS, EBD components), Wheels and Tires Electrical: Battery, Charging System, Starting System, Lighting System, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Power Accessories (Windows, Locks, Seats, Doors), Audio System, Safety Systems (Airbags, Seatbelts) Body: Exterior Body Panels, Interior Trim, Seats, Doors, Windows, Glass, HVAC System Components (ducts, blower motor), Bumpers, Body Sealing Procedures Included Maintenance: Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Belt Inspections and Replacements, Spark Plug Service Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Component Testing Procedures, Symptom-based Diagnostics Repair: Component Removal and Installation, Overhaul Procedures, Adjustments, Component Rebuilding (where applicable) Technical Data: Torque Specifications, P&N (Pressure and Noise) Specifications, Diagnostic Specifications, Alignment Specifications, Component Dimensions Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, including electrical system diagnostics and component-level repair. 📊 Manual Specifications File Format Searchability: Searchable PDF (if digitally sourced), allowing for quick text lookup of specific components or procedures. Print Quality Resolution: High-resolution graphics, diagrams, and schematics for clarity. Professional typesetting. Binding Type Binding: N/A (for digital format, but if physical: spiral-bound or perfect-bound for ease of use in a workshop environment) Paper Type Paper Type: N/A (for digital format, but if physical: durable, coated paper to resist grease and shop contaminants) ⚙️ Engine Specifications Primary Engine Engine Code And Type: 3.8L V6 (EGH), 3.3L V6 (EVE/EVA - less common in these years, but could be present in early models or specific markets) Displacement: 3778 cc (3.8L) Performance Horsepower: Approx. 200-215 hp (varies slightly by year and specific engine variant) Torque: Approx. 230-240 lb-ft (varies slightly by year and specific engine variant) Fuel System Injection Type: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Management ECU: Powertrain Control Module (PCM) - specific part numbers and calibration data covered in manual. Emissions Compliance: Meets EPA/CARB emissions standards for the specified model years. 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle (e.g., 41TE/42LE variant) Optional Transmission Type: 6-speed Automatic Transaxle (may be optional or introduced later in the generation) Features Transmission Control: Electronically Controlled Transmission (ECT) with driver-selectable modes (e.g., Normal, Overdrive Off). Fluid Specifications Atf Type: Chrysler ATF+4 (or equivalent specified by Chrysler for the given transmission) Capacities Fluid Capacity: Approx. 4.0-5.0 quarts (dry fill), approx. 11.0-12.0 quarts (total capacity) - refer to manual for precise figures and procedure. 📐 Dimensions Exterior Length: Approx. 201.0 inches Width: Approx. 77.0 inches Height: Approx. 68.4 inches Wheelbase: Approx. 121.5 inches Interior Passenger Volume: Approx. 150-160 cubic feet (depending on seating configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 30-40 cubic feet Cargo Volume Behind 2Nd Row: Approx. 80-90 cubic feet Cargo Volume Max: Approx. 150-160 cubic feet (seats folded/removed) Weights Curb Weight: Approx. 4,200 - 4,500 lbs (depending on configuration and equipment) Gross Vehicle Weight Rating: Approx. 5,775 - 5,950 lbs Towing Capacity: Approx. 3,800 - 4,000 lbs (with optional towing package) 🛡️ Safety Features Ratings NHTSA Front Impact: 5-star rating (typically for driver and passenger in frontal crash tests for this era) NHTSA Side Impact: 4-star rating (typically for front seats, 3-star for rear seats in side impact tests) IIHS Ratings: Good (typically in frontal offset crash tests, but side impact ratings may vary) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional or standard Traction Control System (TCS) depending on trim level. Electronic Stability Control: Optional Electronic Stability Control (ESC) or similar system (e.g., ESP) may be available. Passive Features Airbags: Frontal airbags (driver and passenger), optional side-impact airbags (front row), optional side-curtain airbags (all rows). Seatbelts: 3-point seatbelts with pretensioners for front seats, 3-point seatbelts for all rear seats. LATCH child seat anchors. Child Safety: Child door locks, integrated child seat...
Suspension (Front and Rear), Steering System, Brake System (ABS, EBD components), Wheels and Tires
Electrical:
Battery, Charging System, Starting System, Lighting System, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Power Accessories (Windows, Locks, Seats, Doors), Audio System, Safety Systems (Airbags, Seatbelts)
Body:
Exterior Body Panels, Interior Trim, Seats, Doors, Windows, Glass, HVAC System Components (ducts, blower motor), Bumpers, Body Sealing
Procedures Included
Maintenance:
Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Belt Inspections and Replacements, Spark Plug Service
Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, including electrical system diagnostics and component-level repair.
📊 Manual Specifications
File Format
Searchability:
Searchable PDF (if digitally sourced), allowing for quick text lookup of specific components or procedures.
Print Quality
Resolution:
High-resolution graphics, diagrams, and schematics for clarity. Professional typesetting.
Binding Type
Binding:
N/A (for digital format, but if physical: spiral-bound or perfect-bound for ease of use in a workshop environment)
Paper Type
Paper Type:
N/A (for digital format, but if physical: durable, coated paper to resist grease and shop contaminants)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
3.8L V6 (EGH), 3.3L V6 (EVE/EVA - less common in these years, but could be present in early models or specific markets)
Displacement:
3778 cc (3.8L)
Performance
Horsepower:
Approx. 200-215 hp (varies slightly by year and specific engine variant)
Torque:
Approx. 230-240 lb-ft (varies slightly by year and specific engine variant)
Fuel System
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU:
Powertrain Control Module (PCM) - specific part numbers and calibration data covered in manual.
Emissions
Compliance:
Meets EPA/CARB emissions standards for the specified model years.
3-point seatbelts with pretensioners for front seats, 3-point seatbelts for all rear seats. LATCH child seat anchors.
Child Safety:
Child door locks, integrated child seat options in some configurations.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional CD/DVD changer, available Sirius Satellite Radio. Uconnect hands-free communication system may be available on higher trims.
Rear Seat Entertainment:
Optional DVD player with flip-down or in-dash screen and wireless headphones.
Driver Assistance
Parking Assist:
Optional rear parking assist sensors.
Connectivity
Remote Keyless Entry:
Standard or optional feature for door unlocking and alarm disarming.
Power Features:
Power windows, power door locks, power adjustable pedals (on some trims), power liftgate.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type (refer to manual for specific Severe vs. Normal service).
Transmission Fluid Change:
Every 30,000-60,000 miles, or as specified by severe service conditions. Crucial for longevity.
Coolant Flush:
Every 30,000-50,000 miles or 2-3 years, depending on coolant type (OAT/HOAT).
Spark Plug Replacement:
Every 60,000-100,000 miles, depending on spark plug type (e.g., platinum or iridium).
Fluid Specifications
Engine Oil Type:
SAE 3.8L: 5W-30 Synthetic or Synthetic Blend. Always verify with manual for specific viscosity and API service category.
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter change.
Coolant Type:
Chrysler HOAT (Hybrid Organic Additive Technology) Pink Antifreeze/Coolant, or equivalent.
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent meeting Chrysler MS-5901.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Transmission Hard Shifting:
Common on earlier models of this generation; can be related to solenoid packs, valve body issues, or fluid/filter service.
Rear Ac Leaks:
Potential for leaks in the rear A/C evaporator or lines, especially in humid climates.
Power Sliding Door Failures:
Motor, switch, or track issues can lead to malfunction of power sliding doors.
Water Pump Leaks:
The 3.8L engine can be prone to water pump leaks over time.
Cv Axle Wear:
Front CV axles may require replacement due to wear, particularly with higher mileage or under heavy use.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan/Plymouth Voyager in the mid-1980s. The Grand Voyager is the long-wheelbase variant.
Model Evolution
Generation:
This represents the fourth generation of the Chrysler minivan platform (RS Body Style continued and evolved into the RT platform in later years, but 2005-2007 often falls into the latter half of the preceding generation or early transition).
Rt Platform Introduction:
The RT platform for the Grand Voyager (along with Dodge Grand Caravan and Chrysler Town & Country) was introduced around 2008. Thus, 2005-2007 Grand Voyagers are typically based on the preceding RS platform, which saw significant updates.
Production
Manufacturing Locations:
Primarily Windsor, Ontario, Canada; St. Louis, Missouri, USA.
Production Years For Generation:
The specific generation covering 2005-2007 began production around 2000/2001 and continued with mid-cycle refreshes.
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Past ratings may have been mixed; often cited for practicality but sometimes criticized for reliability or driving dynamics compared to competitors.
Jd Power Dependability:
May have received average or below-average ratings for dependability in certain model years of this generation.
Family Car Awards:
Often recognized for its spaciousness and family-friendly features in various automotive publications and consumer surveys.
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