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Chrysler Grand Voyager 2000 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Grand Voyager Year: 2000 Codes Chassis Code: NS/GS (European/North American) 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, fleet operators, DIY mechanics Competitive Analysis Key Competitors: Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture Key Features Vehicle Attributes: Spacious interior, flexible seating, family-oriented features, comfortable ride Manual Value Proposition: Enables effective maintenance, diagnosis, and repair, reducing reliance on expensive dealership services 📋 Manual Details Coverage Areas Major Topics: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, HVAC, Diagnosis, Maintenance, Repair Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: 3.3L V6 OHV (EGA), 3.8L V6 OHV (L32) Transmission: 4-speed automatic (41TE, 42LE) Chassis: Front Wheel Drive, Independent Front Suspension (MacPherson Strut), Rear Beam Axle with Coil Springs Steering: Power-assisted rack and pinion Brakes: Front Disc, Rear Drum (standard), Optional ABS Electrical: Complete wiring diagrams, battery, charging system, starting system, lighting, instruments, power accessories, body control modules (BCM) Body: Exterior panels, interior trim, doors, windows, seats, liftgate, styling HVAC: Air conditioning, heating, ventilation, climate control system components Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, tire rotation Engine Repair: Engine removal/installation, cylinder head service, piston/ring replacement, timing component service, gasket replacement Transmission Repair: Transmission removal/installation, internal component repair (clutches, bands, valve body), fluid and filter change Brake Service: Brake pad/shoe replacement, rotor/drum resurfacing/replacement, caliper/wheel cylinder service, brake fluid bleeding Suspension Steering Repair: Strut/shock absorber replacement, ball joint/tie rod end replacement, power steering pump/rack service Electrical Troubleshooting: Diagnostic procedures, circuit testing, component testing, wiring harness repair Bodywork Repair: Panel replacement, dent repair, trim installation/removal, glass replacement Technical Depth Depth: Comprehensive from basic maintenance to major component overhaul and complex diagnostics Diagnostic Tools: Includes procedures for using OBD-II scan tools, multimeter, and specialized Chrysler diagnostic equipment (e.g., DRBIII) Torque Specifications: Detailed torque specifications for all critical fasteners Tolerances: Engine and component clearance specifications for rebuilding 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Printability: Printable for physical workshop use Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 3.3 Liters (3301 cc) Engine 1 Configuration: 3.3L V6 OHV (12 Valve) Engine 1 Bore X Stroke: 93.0 mm x 81.0 mm Engine 1 Compression Ratio: 9.4:1 Engine 1 Horsepower: Approx. 158 hp @ 4800 rpm Engine 1 Torque: Approx. 190 lb-ft @ 3600 rpm Optional Engine Engine 2 Displacement: 3.8 Liters (3778 cc) Engine 2 Configuration: 3.8L V6 OHV (12 Valve) Engine 2 Horsepower: Approx. 180 hp @ 4600 rpm Engine 2 Torque: Approx. 227 lb-ft @ 3200 rpm Performance Fuel Type: Unleaded Gasoline Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Engine Management ECM Type: Chrysler SBEC (Single Board Engine Controller) or similar 🔧 Transmission Standard Type: 4-speed automatic transaxle Model Codes: 41TE, 42LE Optional Optional Transmissions: N/A (All models equipped with automatic) Features Shift Modes: Driver-selectable modes (e.g., Economy, Power) may be present depending on trim Fluid Type Recommended Fluid: ATF+4 (Automatic Transmission Fluid) or equivalent, consult specific vehicle service data Fluid Capacity Capacity Quarts: Approx. 4.5 - 5.0 quarts (dry fill) 📐 Dimensions Exterior Length: Approx. 193.0 inches (4902 mm) Width: Approx. 76.7 inches (1948 mm) Height: Approx. 68.7 inches (1745 mm) Wheelbase: Approx. 112.1 inches (2847 mm) Cargo Cargo Volume Behind 1St Row: Approx. 140.5 cubic feet (40.0 m³) Cargo Volume Behind 2Nd Row: Approx. 77.9 cubic feet (2.2 m³) Cargo Volume Behind 3Rd Row: Approx. 23.4 cubic feet (0.66 m³) Weights Curb Weight: Approx. 4200 - 4500 lbs (1905 - 2041 kg) Gross Vehicle Weight Rating Gvw R: Approx. 5800 - 6000 lbs (2630 - 2722 kg) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (model year dependent, potential variations) NHTSA Frontal Impact Passenger: 4-star (model year dependent, potential variations) IIHS Frontal Offset: Good (for models equipped with dual airbags) Active Features ABS: Available (Anti-lock Braking System) Traction Control: Available on some higher trims Passive Features Airbags: Driver and passenger front airbags standard (side airbags optional on some trims) Seat Belts: 3-point seat belts in all seating positions, front seat belt pretensioners Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system 💡 Technology Features Infotainment Audio System: AM/FM stereo with cassette and CD player, optional premium sound systems Display: Basic digital or analog instrument cluster, no central touchscreen infotainment system Driver Assistance Cruise Control: Standard on most trims Rear Park Assist: Optional on some higher trims Connectivity Remote Keyless Entry: Available on most trims Power Sliding Doors: Optional on some trims 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km)...
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Chrysler Grand Voyager 2000 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Grand Voyager
Year:
2000
Codes
Chassis Code:
NS/GS (European/North American)
👋 Introduction
Market Position
Segment:
Full-size Minivan
Target Audience:
Families, fleet operators, DIY mechanics
Competitive Analysis
Key Competitors:
Ford Windstar, Honda Odyssey, Toyota Sienna, Chevrolet Venture
Key Features
Vehicle Attributes:
Spacious interior, flexible seating, family-oriented features, comfortable ride
Manual Value Proposition:
Enables effective maintenance, diagnosis, and repair, reducing reliance on expensive dealership services
📋 Manual Details
Coverage Areas
Major Topics:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, HVAC, Diagnosis, Maintenance, Repair
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
3.3L V6 OHV (EGA), 3.8L V6 OHV (L32)
Transmission:
4-speed automatic (41TE, 42LE)
Chassis:
Front Wheel Drive, Independent Front Suspension (MacPherson Strut), Rear Beam Axle with Coil Springs
Steering:
Power-assisted rack and pinion
Brakes:
Front Disc, Rear Drum (standard), Optional ABS
Electrical:
Complete wiring diagrams, battery, charging system, starting system, lighting, instruments, power accessories, body control modules (BCM)
Body:
Exterior panels, interior trim, doors, windows, seats, liftgate, styling
HVAC:
Air conditioning, heating, ventilation, climate control system components
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, tire rotation
Engine Repair:
Engine removal/installation, cylinder head service, piston/ring replacement, timing component service, gasket replacement
Transmission Repair:
Transmission removal/installation, internal component repair (clutches, bands, valve body), fluid and filter change
Brake Service:
Brake pad/shoe replacement, rotor/drum resurfacing/replacement, caliper/wheel cylinder service, brake fluid bleeding
Suspension Steering Repair:
Strut/shock absorber replacement, ball joint/tie rod end replacement, power steering pump/rack service
Electrical Troubleshooting:
Diagnostic procedures, circuit testing, component testing, wiring harness repair
Bodywork Repair:
Panel replacement, dent repair, trim installation/removal, glass replacement
Technical Depth
Depth:
Comprehensive from basic maintenance to major component overhaul and complex diagnostics
Diagnostic Tools:
Includes procedures for using OBD-II scan tools, multimeter, and specialized Chrysler diagnostic equipment (e.g., DRBIII)
Torque Specifications:
Detailed torque specifications for all critical fasteners
Tolerances:
Engine and component clearance specifications for rebuilding
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Printability:
Printable for physical workshop use
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
3.3 Liters (3301 cc)
Engine 1 Configuration:
3.3L V6 OHV (12 Valve)
Engine 1 Bore X Stroke:
93.0 mm x 81.0 mm
Engine 1 Compression Ratio:
9.4:1
Engine 1 Horsepower:
Approx. 158 hp @ 4800 rpm
Engine 1 Torque:
Approx. 190 lb-ft @ 3600 rpm
Optional Engine
Engine 2 Displacement:
3.8 Liters (3778 cc)
Engine 2 Configuration:
3.8L V6 OHV (12 Valve)
Engine 2 Horsepower:
Approx. 180 hp @ 4600 rpm
Engine 2 Torque:
Approx. 227 lb-ft @ 3200 rpm
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Engine Management
ECM Type:
Chrysler SBEC (Single Board Engine Controller) or similar
🔧 Transmission
Standard
Type:
4-speed automatic transaxle
Model Codes:
41TE, 42LE
Optional
Optional Transmissions:
N/A (All models equipped with automatic)
Features
Shift Modes:
Driver-selectable modes (e.g., Economy, Power) may be present depending on trim
Fluid Type
Recommended Fluid:
ATF+4 (Automatic Transmission Fluid) or equivalent, consult specific vehicle service data
Fluid Capacity
Capacity Quarts:
Approx. 4.5 - 5.0 quarts (dry fill)
📐 Dimensions
Exterior
Length:
Approx. 193.0 inches (4902 mm)
Width:
Approx. 76.7 inches (1948 mm)
Height:
Approx. 68.7 inches (1745 mm)
Wheelbase:
Approx. 112.1 inches (2847 mm)
Cargo
Cargo Volume Behind 1St Row:
Approx. 140.5 cubic feet (40.0 m³)
Cargo Volume Behind 2Nd Row:
Approx. 77.9 cubic feet (2.2 m³)
Cargo Volume Behind 3Rd Row:
Approx. 23.4 cubic feet (0.66 m³)
Weights
Curb Weight:
Approx. 4200 - 4500 lbs (1905 - 2041 kg)
Gross Vehicle Weight Rating Gvw R:
Approx. 5800 - 6000 lbs (2630 - 2722 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star (model year dependent, potential variations)
NHTSA Frontal Impact Passenger:
4-star (model year dependent, potential variations)
IIHS Frontal Offset:
Good (for models equipped with dual airbags)
Active Features
ABS:
Available (Anti-lock Braking System)
Traction Control:
Available on some higher trims
Passive Features
Airbags:
Driver and passenger front airbags standard (side airbags optional on some trims)
Seat Belts:
3-point seat belts in all seating positions, front seat belt pretensioners
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and CD player, optional premium sound systems
Display:
Basic digital or analog instrument cluster, no central touchscreen infotainment system
Driver Assistance
Cruise Control:
Standard on most trims
Rear Park Assist:
Optional on some higher trims
Connectivity
Remote Keyless Entry:
Available on most trims
Power Sliding Doors:
Optional on some trims
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (synthetic recommended)
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed
Spark Plug Replacement:
Every 60,000-100,000 miles (96,000-160,000 km) depending on spark plug type (e.g., platinum, iridium)
Transmission Fluid Filter Change:
Every 30,000-60,000 miles (48,000-96,000 km), depending on usage
Fluid Specifications
Engine Oil Specification:
API SJ, SAE 5W-30 (check owner's manual for exact recommendation and viscosity for climate)
Coolant Specification:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically Mopar orange or equivalent
Brake Fluid Specification:
DOT 3 or DOT 4, consult manual
Known Issues
Common Complaints:
Rear axle seal leaks, power steering pump issues, HVAC blend door actuator failures, transmission solenoid issues, front suspension component wear (ball joints, tie rods), door lock actuator failures.
Engine Mounts:
Wear and failure of engine and transmission mounts can lead to vibration and noise.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler is credited with inventing the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in the 1980s. The Grand Voyager is an upscale variant.
Model Evolution
Gs Generation Details:
The 2000 model year falls within the second generation (GS) of the Chrysler Voyager/Grand Voyager platform, which ran from 1996 to 2000 (North America) and later in other markets.
Production
Manufacturing Locations:
Primarily Windsor, Ontario, Canada; also Mexico and Austria (for European market variants).
Production Years
Production Span:
1996-2000 (North America)
🏆 Awards & Recognition
Recognitions
Car And Driver Best 10:
The Grand Voyager, as part of the Chrysler minivan family, has historically been recognized on lists like Car and Driver's '10Best' for its segment-defining attributes, though specific awards for the 2000 model year vary.
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