Chrysler Voyager 2003-2007 Service Repair Workshop Manual

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Basic Information Identification Make: Chrysler Model: Voyager Generation: RG (North America) / GW (International) Production Years Covered By Manual: 2003, 2004, 2005, 2006, 2007 Codes Platform: NS (for North American Market) Introduction Market Position Vehicle Segment: Full-size Minivan Target Audience: Families requiring flexible passenger and cargo transport. Competitive Analysis Primary Competitors: Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Uplander, Kia Sedona, Hyundai Entourage Key Features Platform Strength: Known for its practical interior packaging and comfortable ride, particularly in North American configurations. Manual Value Proposition: Provides comprehensive, factory-level repair and maintenance information essential for owners and independent repair facilities. Manual Details Coverage Areas Region Of Origin For Vehicle Design: North America (primarily) Manual Coverage Scope: Full service, repair, and workshop instructions Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive workshop manuals) Manual Type Manual Classification: Factory Service Manual (FSM) / Workshop Manual Language Language Of Manual: English Format Delivery Format: PDF Download Manual Coverage Systems Covered Powertrain Systems: Engine Mechanical, Fuel System, Ignition System, Exhaust System, Engine Control System (ECU/PCM), Automatic Transmission, Manual Transmission (if applicable), Drivetrain Components (CV joints, axles, differentials) Chassis Systems: Braking System (ABS, Hydraulic, Parking Brake), Steering System, Suspension System (Front and Rear), Wheels and Tires Electrical Systems: Body Control Module (BCM), Powertrain Control Module (PCM), HVAC Controls, Lighting System, Audio System, Power Accessories (windows, locks, mirrors), Instrument Panel and Gauges, Wiring Diagrams, Fuses and Relays, Battery and Charging System Body And Trim: Exterior Body Panels, Interior Trim, Seats, Doors, Tailgate, Glass, Body Sealing, Bumpers, Paint and Corrosion Protection HVAC System: Air Conditioning (A/C), Heating, Ventilation, Climate Control System Procedures Included Maintenance Procedures: Scheduled Maintenance, Oil Change, Filter Replacement, Fluid Checks and Replacements, Tire Rotation, Brake Inspection, Belts and Hoses Inspection Repair Procedures: Engine Component Replacement (e.g., spark plugs, water pump, alternator), Transmission Service and Repair, Brake Caliper/Rotor Replacement, Suspension Component Replacement (e.g., ball joints, struts), Electrical Component Diagnosis and Replacement, Body Panel Repair, HVAC System Component Repair Diagnostic Procedures: Troubleshooting Guides, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs), Scan Tool Usage, Electrical Circuit Testing, Component Testing Special Procedures: Torque Specifications, Alignment Procedures, Emission Control System Diagnosis, Body and Frame Alignment Technical Depth Diagnostic Capability: Comprehensive diagnostic information including DTCs, live data interpretation, and step-by-step troubleshooting flowcharts. Mechanical Rebuilds: Detailed instructions for major component overhauls and rebuilds, including engine and transmission. Electrical Schematics: Complete and detailed electrical wiring diagrams for all vehicle systems, essential for electrical fault finding. Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Digital Reproduction Quality: High resolution, designed for clear viewing and printing of diagrams and text. Binding Type Digital Access: Not Applicable (Digital Download) Paper Type Digital Readability: Optimized for screen display and printing on standard paper sizes. Engine Specifications Primary Engine Engine Code 1: 3.3L V6 (EGA) - Naturally Aspirated Engine Code 2: 3.8L V6 (L32/L26) - Naturally Aspirated Performance 3.3L V6 Horsepower: Approx. 180-185 hp (depending on year/trim) 3.3L V6 Torque: Approx. 200-210 lb-ft (depending on year/trim) 3.8L V6 Horsepower: Approx. 200-215 hp (depending on year/trim) 3.8L V6 Torque: Approx. 230-240 lb-ft (depending on year/trim) Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPI) Fuel Type Recommendation: Unleaded gasoline, Octane rating 87 minimum Engine Management Ignition System Type: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or coil pack ignition Transmission Standard Transmission Type Std: 4-speed Automatic Transaxle Optional Transmission Type Opt: Not applicable for this generation, primarily automatic Features Transmission Control: Electronically controlled, Torque converter lock-up clutch Fluid Specifications Automatic Transmission Fluid Type: Chrysler ATF+4 (MS-9602) Fluid Capacity Automatic Transmission Fluid Capacity: Approx. 11.5 - 12.5 quarts (10.9 - 11.8 liters) (dry fill) Dimensions Exterior Wheelbase: Approx. 119.3 inches (3030 mm) Overall Length: Approx. 197.5 inches (5017 mm) Overall Width: Approx. 76.0 inches (1930 mm) Overall Height: Approx. 66.7 inches (1694 mm) Cargo Max Cargo Volume: Approx. 145.4 cu ft (4117 liters) (behind front seats) Weights Curb Weight Range: Approx. 4200 - 4500 lbs (1905 - 2041 kg) (depending on configuration) Gross Vehicle Weight Rating Gvwr: Approx. 5900 - 6100 lbs (2676 - 2767 kg) Safety Features Ratings NHTSA Frontal Impact Driver: Likely 4 stars (based on similar era Chrysler minivans, specific data for 03-07 Voyager may vary) NHTSA Frontal Impact Passenger: Likely 4 stars (based on similar era Chrysler minivans) NHTSA Side Impact Front Seat: Likely 4 stars (based on similar era Chrysler minivans) IIHS Frontal Offset Rating: Acceptable to Good (varies by specific test year, 2005-2007 models generally performed better) Active Features ABS: Standard on all models Traction Control: Available on some models/trims Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front-seat side airbags, optional inflatable curtain airbags (later models) Seatbelts: 3-point seat belts with pretensioners (front row), 3-point seat belts (second and third row) Technology Features Infotainment Audio System Options: Base AM/FM/CD, optional premium audio with amplifier and...

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Tags: 2003 2004 2005 2006 2007 Car Chrysler Marine Misc Outboard Engines Voyager

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Description

Basic Information
Identification
Make:	Chrysler
Model:	Voyager
Generation:	RG (North America) / GW (International)
Production Years Covered By Manual:	2003, 2004, 2005, 2006, 2007
Codes
Platform:	NS (for North American Market)

Introduction
Market Position
Vehicle Segment:	Full-size Minivan
Target Audience:	Families requiring flexible passenger and cargo transport.
Competitive Analysis
Primary Competitors:	Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Uplander, Kia Sedona, Hyundai Entourage
Key Features
Platform Strength:	Known for its practical interior packaging and comfortable ride, particularly in North American configurations.
Manual Value Proposition:	Provides comprehensive, factory-level repair and maintenance information essential for owners and independent repair facilities.

Manual Details
Coverage Areas
Region Of Origin For Vehicle Design:	North America (primarily)
Manual Coverage Scope:	Full service, repair, and workshop instructions
Page Count
Estimated Page Count:	Over 2000 pages (typical for comprehensive workshop manuals)
Manual Type
Manual Classification:	Factory Service Manual (FSM) / Workshop Manual
Language
Language Of Manual:	English
Format
Delivery Format:	PDF Download

Manual Coverage
Systems Covered
Powertrain Systems:	Engine Mechanical, Fuel System, Ignition System, Exhaust System, Engine Control System (ECU/PCM), Automatic Transmission, Manual Transmission (if applicable), Drivetrain Components (CV joints, axles, differentials)
Chassis Systems:	Braking System (ABS, Hydraulic, Parking Brake), Steering System, Suspension System (Front and Rear), Wheels and Tires
Electrical Systems:	Body Control Module (BCM), Powertrain Control Module (PCM), HVAC Controls, Lighting System, Audio System, Power Accessories (windows, locks, mirrors), Instrument Panel and Gauges, Wiring Diagrams, Fuses and Relays, Battery and Charging System
Body And Trim:	Exterior Body Panels, Interior Trim, Seats, Doors, Tailgate, Glass, Body Sealing, Bumpers, Paint and Corrosion Protection
HVAC System:	Air Conditioning (A/C), Heating, Ventilation, Climate Control System
Procedures Included
Maintenance Procedures:	Scheduled Maintenance, Oil Change, Filter Replacement, Fluid Checks and Replacements, Tire Rotation, Brake Inspection, Belts and Hoses Inspection
Repair Procedures:	Engine Component Replacement (e.g., spark plugs, water pump, alternator), Transmission Service and Repair, Brake Caliper/Rotor Replacement, Suspension Component Replacement (e.g., ball joints, struts), Electrical Component Diagnosis and Replacement, Body Panel Repair, HVAC System Component Repair
Diagnostic Procedures:	Troubleshooting Guides, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs), Scan Tool Usage, Electrical Circuit Testing, Component Testing
Special Procedures:	Torque Specifications, Alignment Procedures, Emission Control System Diagnosis, Body and Frame Alignment
Technical Depth
Diagnostic Capability:	Comprehensive diagnostic information including DTCs, live data interpretation, and step-by-step troubleshooting flowcharts.
Mechanical Rebuilds:	Detailed instructions for major component overhauls and rebuilds, including engine and transmission.
Electrical Schematics:	Complete and detailed electrical wiring diagrams for all vehicle systems, essential for electrical fault finding.

Manual Specifications
File Format
Digital Format:	PDF (Portable Document Format)
Print Quality
Digital Reproduction Quality:	High resolution, designed for clear viewing and printing of diagrams and text.
Binding Type
Digital Access:	Not Applicable (Digital Download)
Paper Type
Digital Readability:	Optimized for screen display and printing on standard paper sizes.

Engine Specifications
Primary Engine
Engine Code 1:	3.3L V6 (EGA) - Naturally Aspirated
Engine Code 2:	3.8L V6 (L32/L26) - Naturally Aspirated
Performance
3.3L V6 Horsepower:	Approx. 180-185 hp (depending on year/trim)
3.3L V6 Torque:	Approx. 200-210 lb-ft (depending on year/trim)
3.8L V6 Horsepower:	Approx. 200-215 hp (depending on year/trim)
3.8L V6 Torque:	Approx. 230-240 lb-ft (depending on year/trim)
Fuel System
Fuel Delivery:	Multi-Port Fuel Injection (MPI)
Fuel Type Recommendation:	Unleaded gasoline, Octane rating 87 minimum
Engine Management
Ignition System Type:	Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or coil pack ignition

Transmission
Standard
Transmission Type Std:	4-speed Automatic Transaxle
Optional
Transmission Type Opt:	Not applicable for this generation, primarily automatic
Features
Transmission Control:	Electronically controlled, Torque converter lock-up clutch
Fluid Specifications
Automatic Transmission Fluid Type:	Chrysler ATF+4 (MS-9602)
Fluid Capacity
Automatic Transmission Fluid Capacity:	Approx. 11.5 - 12.5 quarts (10.9 - 11.8 liters) (dry fill)

Dimensions
Exterior
Wheelbase:	Approx. 119.3 inches (3030 mm)
Overall Length:	Approx. 197.5 inches (5017 mm)
Overall Width:	Approx. 76.0 inches (1930 mm)
Overall Height:	Approx. 66.7 inches (1694 mm)
Cargo
Max Cargo Volume:	Approx. 145.4 cu ft (4117 liters) (behind front seats)
Weights
Curb Weight Range:	Approx. 4200 - 4500 lbs (1905 - 2041 kg) (depending on configuration)
Gross Vehicle Weight Rating Gvwr:	Approx. 5900 - 6100 lbs (2676 - 2767 kg)

Safety Features
Ratings
NHTSA Frontal Impact Driver:	Likely 4 stars (based on similar era Chrysler minivans, specific data for 03-07 Voyager may vary)
NHTSA Frontal Impact Passenger:	Likely 4 stars (based on similar era Chrysler minivans)
NHTSA Side Impact Front Seat:	Likely 4 stars (based on similar era Chrysler minivans)
IIHS Frontal Offset Rating:	Acceptable to Good (varies by specific test year, 2005-2007 models generally performed better)
Active Features
ABS:	Standard on all models
Traction Control:	Available on some models/trims
Passive Features
Airbags Front:	Driver and front passenger airbags
Airbags Side:	Optional front-seat side airbags, optional inflatable curtain airbags (later models)
Seatbelts:	3-point seat belts with pretensioners (front row), 3-point seat belts (second and third row)

Technology Features
Infotainment
Audio System Options:	Base AM/FM/CD, optional premium audio with amplifier and subwoofer, optional in-dash 6-disc CD changer.
Rear Seat Entertainment:	Optional DVD entertainment system with flip-down screen available on higher trims from 2005 onwards.
Driver Assistance
Cruise Control:	Standard feature across most trims.
Parking Assistance:	Optional rear parking assist sensors (ParkSense) available on later models.
Connectivity
Auxiliary Input:	Not standard; typically requires aftermarket modification for auxiliary audio input on factory radios.
Comfort Features
Seating Configurations:	Available in 7-passenger (2-2-3) or 8-passenger (2-3-3) configurations with Stow 'n Go seating not yet introduced in this generation. Second-row captain's chairs or bench, third-row bench seat.

Maintenance
Service Intervals
Oil Change Interval:	Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions. Consult manual for severe service intervals.
Engine Air Filter Replacement:	Inspect every 15,000 miles (24,000 km), replace as needed or approximately every 30,000 miles (48,000 km).
Cabin Air Filter Replacement:	Replace every 15,000-30,000 miles (24,000-48,000 km) or annually, depending on environment.
Transmission Fluid Service:	Inspect fluid level and condition every 15,000 miles (24,000 km). Fluid and filter change typically recommended every 60,000-100,000 miles (96,000-160,000 km) or as per severe service schedule.
Spark Plug Replacement:	3.3L V6: Approx. 100,000 miles (160,000 km) with platinum/iridium plugs. 3.8L V6: Approx. 100,000 miles (160,000 km) with platinum/iridium plugs.
Fluid Specifications
Engine Oil Viscosity:	SAE 3.80W-30 or 3.90W-30 (check owner's manual for specific engine variant)
Engine Oil Capacity:	Approx. 4.5 - 5.0 quarts (4.3 - 4.7 liters) (depending on engine)
Coolant Type:	Chrysler HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant, Pink color (MS-9769)
Coolant Capacity:	Approx. 12.0 - 13.0 quarts (11.4 - 12.3 liters)
Brake Fluid Type:	DOT 3
Known Issues
Transmission Issues:	Potential for torque converter shudder or clutch wear in high-mileage vehicles. The 41TE/AE transmission is generally robust but requires regular fluid maintenance.
Engine Issues:	Oil leaks from valve cover gaskets or oil pan, occasional radiator/hose failures, alternator failures are relatively common.
Suspension Issues:	Worn ball joints, tie rod ends, and control arm bushings can lead to steering looseness and tire wear.
Electrical Issues:	Faulty power window regulators, issues with the BCM (Body Control Module), and HVAC blower motor resistor failure are notable.
Exhaust System:	Exhaust manifold cracks on V6 engines can lead to ticking noises and exhaust leaks.

Vehicle History
Brand Heritage
Chrysler Minivan Legacy:	Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983. The Voyager nameplate was used for international markets and later for certain North American versions.
Model Evolution
Rg Generation Introduction:	The RG Voyager (North American variant of the RS platform) debuted for the 2001 model year and continued through 2007 with minor updates.
Key Updates 2003-2007:	Introduction of the 3.8L engine option, revised interior appointments, updated exterior styling (grille, headlights, taillights) for 2005 model year, available DVD entertainment system.
Production
Manufacturing Locations:	Primarily Windsor, Ontario, Canada; St. Louis, Missouri, USA (for some platforms).
Discontinuation Of Voyager Nameplate Na:	The Voyager nameplate was largely phased out in North America in favor of the Grand Caravan and Town & Country, though it continued in some international markets. For 2008, the North American minivan line was consolidated under the Grand Caravan and Town & Country.

Awards & Recognition
Recognitions
Edmunds Reviews:	Often cited for spaciousness and value, though sometimes criticized for interior material quality compared to Japanese rivals.
Car And Driver Comparisons:	Frequently featured in family minivan comparisons, highlighting its practicality and American-market appeal.
Ratings
Kbb Consumer Ratings:	Generally received positive consumer reviews for reliability in core components and practicality, with some variation in user satisfaction regarding specific electronic or minor issues.