Chrysler Voyager 2001 Service Repair Workshop Manual

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Basic Information Identification Make: Chrysler Model: Voyager Year: 2001 Chassis Code: GS (Second Generation, Facelift) Platform: Chrysler NS minivan platform Introduction Market Position Segment: Mid-size Minivan Target Demographic: Families, individuals requiring versatile passenger and cargo capacity. Competitive Analysis Key Competitors 2001: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, Buick Terraza (though later). Key Features Versatility: Flexible seating arrangements, ample cargo space, practical for family use. Styling: Facelifted GS generation offered a more modern and refined appearance compared to earlier models. Value Proposition: Often positioned as a more affordable option compared to Japanese competitors. Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Intended Audience: Professional Mechanics and DIY Enthusiasts Source Type: Factory Service Information Page Count Estimated Page Count: Likely over 1500 pages (typical for a comprehensive factory service manual for this era). Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnostics, component testing, internal repair procedures for all engine variants. Engine Electrical: Ignition system, fuel injection, emissions control, starter, alternator, ECU diagnostics, wiring diagrams. Transmission Automatic: Service, repair, overhaul, diagnostics, fluid change, torque converter service for the 4-speed automatic transmission. Transmission Manual: If applicable to specific trims, service, repair, and overhaul procedures. Drivetrain: Front-wheel drive (FWD) axle and CV joint service, differential service, wheel bearing replacement. Suspension: Front and rear suspension component replacement (struts, shocks, control arms, ball joints, bushings), alignment specifications. Steering: Power steering system diagnosis, repair, fluid service, steering column and linkage service. Brakes: Disc brake service (pads, rotors, calipers), drum brake service (shoes, drums, wheel cylinders), ABS system diagnosis and repair, brake bleeding procedures. HVAC: Air conditioning system service, refrigerant handling, heater core replacement, blower motor service, climate control system diagnostics. Electrical Body: Lighting system, power windows, power locks, door modules, interior lighting, exterior lighting, fuse box locations, relay functions, body control module (BCM) diagnostics. Body Interior: Interior trim removal and installation, seat removal, dashboard disassembly, carpet replacement, door panel removal. Body Exterior: Body panel replacement (fenders, doors, hood, tailgate), bumper repair and replacement, glass replacement (windshield, side windows, rear glass), weatherstripping. Exhaust System: Exhaust component replacement (mufflers, catalytic converters, pipes), gasket replacement, exhaust system diagnostics. Fuel System: Fuel pump replacement, fuel filter replacement, fuel injectors, fuel tank service, EVAP system diagnostics. Cooling System: Radiator replacement, water pump service, thermostat replacement, coolant flush and fill, fan clutch/motor replacement, pressure testing. Procedures Included Scheduled Maintenance: Detailed maintenance schedules for oil changes, filter replacements, fluid checks, tune-ups, and inspections based on mileage and time. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for common and complex issues across all major systems. Repair Rebuild: Step-by-step instructions for the disassembly, repair, reassembly, and adjustment of virtually all vehicle components. Diagnostics: OBD-II diagnostic trouble code (DTC) interpretation, specific sensor testing, module communication diagnostics. Torque Specifications: Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for all vehicle circuits, essential for electrical diagnostics and repairs. Special Tools: Identification and usage instructions for any specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive from basic fluid changes and filter replacements to complete engine and transmission rebuilds, including complex electrical system diagnostics and bodywork repairs. Manual Specifications File Format File Type: PDF Searchable Text: Yes, assuming a professionally scanned and OCR'd PDF. Printability: Printable pages for easy workshop use. Quality: High-resolution scans for clear diagrams and text. Engine Specifications Primary Engine Engine Code Usa: EGA (3.0L V6 OHV) Engine Code Europe: EGE (3.3L V6 OHV), EGD (2.4L I4 OHV) Displacement Usa: 182 cu in (3.0 Liters) Displacement Europe: 201 cu in (3.3 Liters) or 148 cu in (2.4 Liters) Horsepower Usa 3.0L: 150 hp @ 5000 rpm (approx.) Torque Usa 3.0L: 170 lb-ft @ 3500 rpm (approx.) Horsepower Europe 3.3L: 158 hp @ 4700 rpm (approx.) Torque Europe 3.3L: 195 lb-ft @ 3700 rpm (approx.) Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 AKI (Octane Rating) Transmission Standard Transmission Type: 4-speed automatic (e.g., 41TE, 42LE) Optional Transmission Type: Some markets might have offered manual transmissions on 4-cylinder models, though less common for the Voyager nameplate. Features Gear Ratios: Detailed ratios provided within the manual for all forward gears and reverse. Transmission Fluid Type: ATF+4 (Chrysler Automatic Transmission Fluid, Type 9602) Transmission Fluid Capacity W O Converter: Approx. 6.0 quarts (5.7 Liters) Transmission Fluid Capacity W Converter: Approx. 8.8 quarts (8.3 Liters) Dimensions Exterior Length: Approx. 189.2 inches (4806 mm) Width: Approx. 72.1 inches (1831 mm) Height: Approx. 67.9 inches (1725 mm) Wheelbase: Approx. 112.1 inches (2847 mm) Weights Curb Weight: Approx. 3600-4000 lbs (1633-1814 kg), varies by configuration. Cargo Cargo Volume Behind 3Rd Row: Approx. 15.0-20.0 cu ft (425-566 Liters) Cargo Volume With 3Rd Row Folded: Approx. 70.0-80.0 cu ft (1982-2265 Liters) Cargo Volume With...

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Description

Basic Information
Identification
Make:	Chrysler
Model:	Voyager
Year:	2001
Chassis Code:	GS (Second Generation, Facelift)
Platform:	Chrysler NS minivan platform

Introduction
Market Position
Segment:	Mid-size Minivan
Target Demographic:	Families, individuals requiring versatile passenger and cargo capacity.
Competitive Analysis
Key Competitors 2001:	Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture, Pontiac Montana, Buick Terraza (though later).
Key Features
Versatility:	Flexible seating arrangements, ample cargo space, practical for family use.
Styling:	Facelifted GS generation offered a more modern and refined appearance compared to earlier models.
Value Proposition:	Often positioned as a more affordable option compared to Japanese competitors.

Manual Details
Coverage Areas
Manual Type:	Service Repair Workshop Manual
Language:	English
Format:	PDF Download
Intended Audience:	Professional Mechanics and DIY Enthusiasts
Source Type:	Factory Service Information
Page Count
Estimated Page Count:	Likely over 1500 pages (typical for a comprehensive factory service manual for this era).

Manual Coverage
Systems Covered
Engine Mechanical:	Complete overhaul, diagnostics, component testing, internal repair procedures for all engine variants.
Engine Electrical:	Ignition system, fuel injection, emissions control, starter, alternator, ECU diagnostics, wiring diagrams.
Transmission Automatic:	Service, repair, overhaul, diagnostics, fluid change, torque converter service for the 4-speed automatic transmission.
Transmission Manual:	If applicable to specific trims, service, repair, and overhaul procedures.
Drivetrain:	Front-wheel drive (FWD) axle and CV joint service, differential service, wheel bearing replacement.
Suspension:	Front and rear suspension component replacement (struts, shocks, control arms, ball joints, bushings), alignment specifications.
Steering:	Power steering system diagnosis, repair, fluid service, steering column and linkage service.
Brakes:	Disc brake service (pads, rotors, calipers), drum brake service (shoes, drums, wheel cylinders), ABS system diagnosis and repair, brake bleeding procedures.
HVAC:	Air conditioning system service, refrigerant handling, heater core replacement, blower motor service, climate control system diagnostics.
Electrical Body:	Lighting system, power windows, power locks, door modules, interior lighting, exterior lighting, fuse box locations, relay functions, body control module (BCM) diagnostics.
Body Interior:	Interior trim removal and installation, seat removal, dashboard disassembly, carpet replacement, door panel removal.
Body Exterior:	Body panel replacement (fenders, doors, hood, tailgate), bumper repair and replacement, glass replacement (windshield, side windows, rear glass), weatherstripping.
Exhaust System:	Exhaust component replacement (mufflers, catalytic converters, pipes), gasket replacement, exhaust system diagnostics.
Fuel System:	Fuel pump replacement, fuel filter replacement, fuel injectors, fuel tank service, EVAP system diagnostics.
Cooling System:	Radiator replacement, water pump service, thermostat replacement, coolant flush and fill, fan clutch/motor replacement, pressure testing.
Procedures Included
Scheduled Maintenance:	Detailed maintenance schedules for oil changes, filter replacements, fluid checks, tune-ups, and inspections based on mileage and time.
Troubleshooting:	Diagnostic flowcharts and symptom-based troubleshooting guides for common and complex issues across all major systems.
Repair Rebuild:	Step-by-step instructions for the disassembly, repair, reassembly, and adjustment of virtually all vehicle components.
Diagnostics:	OBD-II diagnostic trouble code (DTC) interpretation, specific sensor testing, module communication diagnostics.
Torque Specifications:	Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage.
Wiring Diagrams:	Comprehensive and detailed electrical wiring diagrams for all vehicle circuits, essential for electrical diagnostics and repairs.
Special Tools:	Identification and usage instructions for any specialized tools required for specific repair procedures.
Technical Depth
Depth:	Comprehensive from basic fluid changes and filter replacements to complete engine and transmission rebuilds, including complex electrical system diagnostics and bodywork repairs.

Manual Specifications
File Format
File Type:	PDF
Searchable Text:	Yes, assuming a professionally scanned and OCR'd PDF.
Printability:	Printable pages for easy workshop use.
Quality:	High-resolution scans for clear diagrams and text.

Engine Specifications
Primary Engine
Engine Code Usa:	EGA (3.0L V6 OHV)
Engine Code Europe:	EGE (3.3L V6 OHV), EGD (2.4L I4 OHV)
Displacement Usa:	182 cu in (3.0 Liters)
Displacement Europe:	201 cu in (3.3 Liters) or 148 cu in (2.4 Liters)
Horsepower Usa 3.0L:	150 hp @ 5000 rpm (approx.)
Torque Usa 3.0L:	170 lb-ft @ 3500 rpm (approx.)
Horsepower Europe 3.3L:	158 hp @ 4700 rpm (approx.)
Torque Europe 3.3L:	195 lb-ft @ 3700 rpm (approx.)
Fuel System
Fuel Delivery:	Multi-point fuel injection (MPI)
Fuel Type:	Unleaded gasoline
Recommended Octane:	87 AKI (Octane Rating)

Transmission
Standard
Transmission Type:	4-speed automatic (e.g., 41TE, 42LE)
Optional
Transmission Type:	Some markets might have offered manual transmissions on 4-cylinder models, though less common for the Voyager nameplate.
Features
Gear Ratios:	Detailed ratios provided within the manual for all forward gears and reverse.
Transmission Fluid Type:	ATF+4 (Chrysler Automatic Transmission Fluid, Type 9602)
Transmission Fluid Capacity W O Converter:	Approx. 6.0 quarts (5.7 Liters)
Transmission Fluid Capacity W Converter:	Approx. 8.8 quarts (8.3 Liters)

Dimensions
Exterior
Length:	Approx. 189.2 inches (4806 mm)
Width:	Approx. 72.1 inches (1831 mm)
Height:	Approx. 67.9 inches (1725 mm)
Wheelbase:	Approx. 112.1 inches (2847 mm)
Weights
Curb Weight:	Approx. 3600-4000 lbs (1633-1814 kg), varies by configuration.
Cargo
Cargo Volume Behind 3Rd Row:	Approx. 15.0-20.0 cu ft (425-566 Liters)
Cargo Volume With 3Rd Row Folded:	Approx. 70.0-80.0 cu ft (1982-2265 Liters)
Cargo Volume With 2Nd And 3Rd Rows Folded:	Approx. 140.0-150.0 cu ft (3963-4247 Liters)

Safety Features
Ratings
NHTSA Front Crash Test:	Generally performed well for its class in frontal impacts (specific star ratings may vary).
IIHS Side Impact:	Refer to IIHS reports for specific model year performance; generally improved with facelifts.
Active Features
ABS:	Standard Anti-lock Braking System on most trims.
Traction Control:	Optional or standard on higher trims, often referred to as Traction Control System (TCS).
Passive Features
Airbags:	Driver and passenger front airbags; optional side airbags.
Seat Belts:	Three-point seat belts for all seating positions, front seat belt pretensioners.

Technology Features
Infotainment
Audio System:	Factory-installed AM/FM/CD players, optional cassette players, premium sound system options.
Rear Seat Entertainment:	Optional rear-seat video entertainment systems with integrated screens were available on higher trims.
Driver Assistance
Cruise Control:	Standard on most models.
Parking Assist:	Optional rear parking assist sensors available on some higher trims.
Connectivity
Power Outlets:	Multiple 12V accessory power outlets for charging devices.

Maintenance
Service Intervals
Oil Change Interval:	Every 3,000-7,500 miles (4,800-12,000 km) or 6 months, depending on driving conditions and oil type used. Refer to manual for specific recommendations.
Air Filter Replacement:	Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:	Typically every 60,000-100,000 miles (96,000-160,000 km) for platinum or iridium plugs, depending on engine and plug type. Refer to manual for exact specifications.
Transmission Fluid Change:	Every 30,000-60,000 miles (48,000-96,000 km), or sooner under severe service conditions. Essential for longevity of the automatic transmission.
Fluid Specifications
Engine Oil Type:	SAE 5W-30 (or 10W-30 depending on ambient temperature). Consult manual for precise viscosity grade and API service classification.
Engine Oil Capacity:	Approx. 4.5-5.0 quarts (4.3-4.7 Liters) for 3.0L V6. Consult manual.
Coolant Type:	Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically a Mopar OAT or equivalent, usually orange or pink in color. Do NOT mix with older green OAT coolants.
Brake Fluid Type:	DOT 3 or DOT 4 (consult manual for specific recommendation, DOT 4 preferred for improved boiling point).
Known Issues
Transmission Problems:	Common complaints include slipping, harsh shifting, and solenoid issues in the automatic transmissions, often exacerbated by overheating or lack of fluid changes.
Ignition System:	Premature failure of ignition coils and spark plug wires (on older designs) can lead to misfires.
Power Steering:	Leaky power steering pumps and hoses, or worn steering racks can occur.
Rear Suspension:	Worn rear springs or sagging suspension due to age and load carrying can be an issue.
Climate Control:	HVAC blend door actuators, blower motor resistor failures, and AC leaks are common.

Vehicle History
Brand Heritage
Chrysler Minivan Legacy:	Chrysler pioneered the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in 1984, setting industry standards.
Model Evolution
Gs Generation Facelift:	The 2001 model is part of the second generation (GS), which received a significant facelift for the 2001 model year, introducing updated styling, interior features, and powertrain refinements.
Previous Generation:	First generation (AS) ran from 1996-2000.
Production
Manufacturing Locations:	Primarily St. Louis, Missouri, USA (Chrysler's main minivan assembly plant).
Market Availability:	North America (USA, Canada, Mexico), Europe (as Chrysler Voyager), and other international markets. Badge engineering also saw versions as Dodge Grand Caravan and Plymouth Grand Voyager.

Awards & Recognition
Recognitions
Car And Driver 10Best:	While the Voyager itself might not have made the 10Best list directly, Chrysler minivans as a platform were often praised for their innovation and practicality, influencing the segment significantly.
Ratings
Consumer Reports:	Consumer Reports reliability ratings varied by model year and specific issues, but the platform was generally seen as functional for its purpose.