Chrysler Voyager 2003-2007 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Voyager Years Covered: 2003, 2004, 2005, 2006, 2007 Generation Generation Name: GS (Fourth Generation) Codes Chassis Code: RS 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, individuals needing ample passenger and cargo space, DIY mechanics, professional repair shops. Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Montana. Key Features Vehicle Sliding Doors: Power-operated sliding doors (driver and passenger side) were a hallmark feature for easy access. Seating Capacity: Typically offered in 7- or 8-passenger configurations with flexible seating arrangements. Cargo Space: Generous cargo volume with Stow 'n Go or similar fold-flat seating options in some trims/later models (though this specific generation might predate widespread Stow 'n Go). Key Features Manual Completeness: This is the official factory manual, ensuring accuracy and completeness for all service procedures. Utility: Indispensable for accurate diagnostics, proper repairs, and preventative maintenance, saving time and money compared to guesswork or less comprehensive guides. 📋 Manual Details Coverage Areas Regions Covered: Primarily North America (USA, Canada), but also applicable to global markets where the Chrysler Voyager (or its rebadged variants like Dodge Grand Caravan, Plymouth Grand Voyager in earlier iterations, and Volkswagen Routan later) was sold. Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECM/PCM), emissions control. Transmission: Automatic transmission (e.g., 41TE, 42LE) service, diagnostics, repair, torque converter, valve body, planetary gears, hydraulic controls, electronic controls. Drivetrain: Front-wheel drive system, axles, CV joints, differential. Brakes: Front and rear brake systems (disc/drum configurations), ABS, hydraulic components, service procedures, rotor/pad replacement, caliper service. Suspension Steering: Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), steering gear, power steering system, wheel alignment specifications. Electrical Electronics: 12V electrical system, battery, charging system (alternator), starting system, lighting, body control module (BCM), instrument cluster, wiring diagrams, fuse/relay information, diagnostic trouble codes (DTCs). HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, compressor, condenser, evaporator, blower motor, climate control module. Body Chassis: Body panels, doors, hinges, latches, interior trim, glass, seals, chassis components, rustproofing. Comfort Convenience: Power windows, power locks, power sliding doors, power liftgate, remote keyless entry, cruise control, power seats, mirrors. Safety Restraint: Airbag system, seat belts, SRS module, diagnostics and repair of safety restraint systems. Procedures Included Maintenance: Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, brake fluid flush, coolant flush, tire rotation, air filter replacement. Diagnostics: Troubleshooting charts, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation, electrical system diagnostics, common faults and remedies. Repair: Engine component repair (e.g., head gasket, timing belt/chain), transmission rebuild, brake caliper replacement, suspension component replacement, fuel pump replacement, alternator replacement, starter replacement. Installation Replacement: Component replacement procedures for all major systems, including body panels, interior components, and electrical modules. Specifications: Torque specifications for all fasteners, fluid capacities, diagnostic parameters, electrical component resistance values, clearances. Technical Depth Depth: Comprehensive. Covers everything from routine maintenance and basic repairs to advanced diagnostics, major component overhauls, and full system diagnostics. Diagrams: Includes detailed schematics, wiring diagrams, exploded views, and diagnostic flowcharts. Troubleshooting Guides: Extensive symptom-based troubleshooting guides for common and uncommon issues. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Printability: Printable pages, allowing users to create a physical copy. Binding Type Binding Type Physical: N/A (Digital PDF Download) Paper Type Paper Type Physical: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code And Displacement: 3.3L V6 (EGA engine family, e.g., EGA/EGH) and 3.8L V6 (L32 engine family). Performance Horsepower 3.3L: Approximately 180-185 hp @ 5000-5200 rpm (depending on specific variant and year). Torque 3.3L: Approximately 205-210 lb-ft @ 3400-4000 rpm. Horsepower 3.8L: Approximately 200-215 hp @ 5000-5200 rpm. Torque 3.8L: Approximately 230-245 lb-ft @ 3000-3400 rpm. Fuel System Induction: Sequential Multi-Port Fuel Injection (MPI). Fuel Type: Unleaded gasoline. Engine Construction Block Material: Cast Iron Cylinder Head Material: Aluminum Cooling System Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) - typically OAT Red/Pink or IAT Green for older models, consult manual for specific spec (MS-9769 or equivalent). Lubrication System Oil Type: SAE 5W-30 Synthetic or Conventional (check manual for specific viscosity and API service classification). Oil Capacity: Approximately 4.5 US quarts (4.3 liters) with filter for 3.3L/3.8L V6. Timing System Timing Mechanism 3.3L: Timing Chain (internal). Timing Mechanism 3.8L: Timing Chain (internal). 🔧 Transmission Standard Type: 4-speed Automatic Transaxle (e.g., 41TE, 42LE). Optional Transmission Options: No manual transmission offered for this model/year range. Features Electronic Control: Electronically controlled for optimal shift points and efficiency. Fluid Specifications Fluid Type: ATF+4 (Automatic Transmission Fluid type 4) - Chrysler material number 05013457AA or equivalent. Fluid Capacity Capacity: Approximately 4.0-4.5 US quarts (3.8-4.3 liters)...

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Type: Car

Verkoper:

Sku: 74499

Collecties: ALL Chrysler Marine

Beschikbaarheid: Op voorraad

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

Productvarianten

Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Voyager

Years Covered:

2003, 2004, 2005, 2006, 2007

Generation

Generation Name:

GS (Fourth Generation)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Full-size Minivan

Target Audience:

Families, individuals needing ample passenger and cargo space, DIY mechanics, professional repair shops.

Competitive Analysis

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Montana.

Key Features Vehicle

Sliding Doors:

Power-operated sliding doors (driver and passenger side) were a hallmark feature for easy access.

Seating Capacity:

Typically offered in 7- or 8-passenger configurations with flexible seating arrangements.

Cargo Space:

Generous cargo volume with Stow 'n Go or similar fold-flat seating options in some trims/later models (though this specific generation might predate widespread Stow 'n Go).

Key Features Manual

Completeness:

This is the official factory manual, ensuring accuracy and completeness for all service procedures.

Utility:

Indispensable for accurate diagnostics, proper repairs, and preventative maintenance, saving time and money compared to guesswork or less comprehensive guides.

📋 Manual Details

Coverage Areas

Regions Covered:

Primarily North America (USA, Canada), but also applicable to global markets where the Chrysler Voyager (or its rebadged variants like Dodge Grand Caravan, Plymouth Grand Voyager in earlier iterations, and Volkswagen Routan later) was sold.

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECM/PCM), emissions control.

Transmission:

Automatic transmission (e.g., 41TE, 42LE) service, diagnostics, repair, torque converter, valve body, planetary gears, hydraulic controls, electronic controls.

Drivetrain:

Front-wheel drive system, axles, CV joints, differential.

Brakes:

Front and rear brake systems (disc/drum configurations), ABS, hydraulic components, service procedures, rotor/pad replacement, caliper service.

Suspension Steering:

Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), steering gear, power steering system, wheel alignment specifications.

Electrical Electronics:

12V electrical system, battery, charging system (alternator), starting system, lighting, body control module (BCM), instrument cluster, wiring diagrams, fuse/relay information, diagnostic trouble codes (DTCs).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, compressor, condenser, evaporator, blower motor, climate control module.

Body Chassis:

Body panels, doors, hinges, latches, interior trim, glass, seals, chassis components, rustproofing.

Comfort Convenience:

Power windows, power locks, power sliding doors, power liftgate, remote keyless entry, cruise control, power seats, mirrors.

Safety Restraint:

Airbag system, seat belts, SRS module, diagnostics and repair of safety restraint systems.

Procedures Included

Maintenance:

Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, brake fluid flush, coolant flush, tire rotation, air filter replacement.

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation, electrical system diagnostics, common faults and remedies.

Repair:

Engine component repair (e.g., head gasket, timing belt/chain), transmission rebuild, brake caliper replacement, suspension component replacement, fuel pump replacement, alternator replacement, starter replacement.

Installation Replacement:

Component replacement procedures for all major systems, including body panels, interior components, and electrical modules.

Specifications:

Torque specifications for all fasteners, fluid capacities, diagnostic parameters, electrical component resistance values, clearances.

Technical Depth

Depth:

Comprehensive. Covers everything from routine maintenance and basic repairs to advanced diagnostics, major component overhauls, and full system diagnostics.

Diagrams:

Includes detailed schematics, wiring diagrams, exploded views, and diagnostic flowcharts.

Troubleshooting Guides:

Extensive symptom-based troubleshooting guides for common and uncommon issues.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text for quick information retrieval.

Print Quality

Printability:

Printable pages, allowing users to create a physical copy.

Binding Type

Binding Type Physical:

N/A (Digital PDF Download)

Paper Type

Paper Type Physical:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code And Displacement:

3.3L V6 (EGA engine family, e.g., EGA/EGH) and 3.8L V6 (L32 engine family).

Performance

Horsepower 3.3L:

Approximately 180-185 hp @ 5000-5200 rpm (depending on specific variant and year).

Torque 3.3L:

Approximately 205-210 lb-ft @ 3400-4000 rpm.

Horsepower 3.8L:

Approximately 200-215 hp @ 5000-5200 rpm.

Torque 3.8L:

Approximately 230-245 lb-ft @ 3000-3400 rpm.

Fuel System

Induction:

Sequential Multi-Port Fuel Injection (MPI).

Fuel Type:

Unleaded gasoline.

Engine Construction

Block Material:

Cast Iron

Cylinder Head Material:

Aluminum

Cooling System

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) - typically OAT Red/Pink or IAT Green for older models, consult manual for specific spec (MS-9769 or equivalent).

Lubrication System

Oil Type:

SAE 5W-30 Synthetic or Conventional (check manual for specific viscosity and API service classification).

Oil Capacity:

Approximately 4.5 US quarts (4.3 liters) with filter for 3.3L/3.8L V6.

Timing System

Timing Mechanism 3.3L:

Timing Chain (internal).

Timing Mechanism 3.8L:

Timing Chain (internal).

🔧 Transmission

Standard

Type:

4-speed Automatic Transaxle (e.g., 41TE, 42LE).

Optional

Transmission Options:

No manual transmission offered for this model/year range.

Features

Electronic Control:

Electronically controlled for optimal shift points and efficiency.

Fluid Specifications

Fluid Type:

ATF+4 (Automatic Transmission Fluid type 4) - Chrysler material number 05013457AA or equivalent.

Fluid Capacity

Capacity:

Approximately 4.0-4.5 US quarts (3.8-4.3 liters) for a drain and fill.

📐 Dimensions

Exterior

Length:

Approximately 194.7 inches (4945 mm).

Width:

Approximately 77.0 inches (1956 mm).

Height:

Approximately 68.5 inches (1740 mm).

Wheelbase:

Approximately 119.2 inches (3028 mm).

Weights

Curb Weight Range:

Approximately 4,100 - 4,400 lbs (1860 - 2000 kg).

Cargo

Max Cargo Volume:

Exceeds 140 cubic feet (approx. 4.0 cubic meters) behind the first row seats.

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Likely 4-star (Good) or 5-star (Excellent) depending on specific test protocols and year. Consult NHTSA archives for precise data.

NHTSA Front Impact Passenger:

Likely 4-star (Good) or 5-star (Excellent).

NHTSA Side Impact Front Seat:

Likely 4-star (Good) or 5-star (Excellent).

NHTSA Side Impact Rear Seat:

Likely 4-star (Good) or 5-star (Excellent).

IIHS Front Small Overlap:

Not applicable for this generation as the test was not widely implemented.

Active Features

Standard Anti-lock Braking System (ABS) on all models.

Traction Control:

Optional Traction Control System (TCS) available on some trims.

Passive Features

Airbags Front:

Driver and front passenger advanced airbags.

Airbags Side:

Optional or standard side-impact airbags for front occupants in later model years.

Seatbelts:

Height-adjustable front seat belts, three-point seat belts for all seating positions.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

💡 Technology Features

Infotainment

Audio System:

Various audio systems available, including AM/FM stereo with CD player, cassette player (on early models), and optional premium audio systems with amplifiers and multiple speakers.

Navigation:

Optional factory-installed or dealer-installed navigation systems were available, often integrated into the dashboard.

Driver Assistance

Cruise Control:

Standard cruise control.

Rear Park Assist:

Optional rear parking assist sensors were available on some trims.

Connectivity

Remote Keyless Entry:

Standard or optional remote keyless entry system.

Power Features:

Power windows, power door locks, and often power rear quarter windows.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used. Consult manual for precise interval based on Severe/Normal service.

Tire Rotation Interval:

Every 5,000-7,500 miles (8,000-12,000 km).

Transmission Fluid Change:

Recommended every 30,000-60,000 miles (48,000-96,000 km), or as per severe service schedule. Crucial for ATF+4 longevity.

Coolant Flush Interval:

Initial flush at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter (for HOAT coolant).

Spark Plug Replacement:

3.3L V6: ~100,000 miles (160,000 km) with platinum-tipped plugs. 3.8L V6: ~100,000 miles (160,000 km) with platinum-tipped plugs.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid (consult manual for specific recommendation).

Power Steering Fluid:

ATF+4 or Pentastar Power Steering Fluid (consult manual for exact spec).

Windshield Washer Fluid:

Automotive windshield washer fluid concentrate or ready-to-use mixture.

Known Issues

Transmission Failures:

The 41TE/42LE transmissions, while generally robust, can experience issues like solenoid failure, torque converter clutch (TCC) shudder, or internal seal leaks if not maintained with proper fluid changes.

Power Sliding Door Motors:

The electric motors and mechanisms for the power sliding doors can wear out or fail, leading to slow operation or complete failure.

Wiper Motor:

Windshield wiper motor failure is a common complaint.

Heater Core:

Heater core leaks can occur, often resulting in coolant loss and a sweet smell inside the cabin.

Suspension Components:

Wear on ball joints, tie rod ends, and control arm bushings can lead to steering looseness and premature tire wear.

Cv Axles:

Front CV axle boots can tear, leading to grease loss and eventual CV joint failure.

📚 Vehicle History

Brand Heritage

Minivan Pioneering:

Chrysler is widely credited with inventing the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in 1984.

Model Evolution

Fourth Generation Introduction:

The GS generation (2001-2007) represented a significant redesign of the original minivan platform, moving to a more car-like unibody construction and modern styling.

Segment Naming:

Chrysler branded its minivans under the Chrysler Voyager nameplate globally, while in North America, the similar vehicles were also sold as Dodge Grand Caravan and formerly Plymouth Grand Voyager.

Production

Assembly Locations:

Primarily Windsor, Ontario, Canada; St. Louis, Missouri, USA.

Production Years Platform:

2001-2007 for the GS platform.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Minivans of this era, including variants of the Chrysler/Dodge platform, were frequent recipients of '10Best' awards from publications like Car and Driver in their respective production years for their practicality and innovation.

Ratings

Consumer Satisfaction:

Often rated highly for utility and interior space by consumer satisfaction surveys, though specific reliability ratings could vary by year and component.