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CHRYSLER Grand VOYAGER 2008-2013 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Grand Voyager Generation: RT Platform Year Range: 2008-2013 Codes Platform Code: RT 👋 Introduction Market Position Segment: Full-size Minivan Target Audience: Families, fleet operators, DIY mechanics, professional technicians. Competitive Analysis Key Competitors: Dodge Grand Caravan (platform sharing), Honda Odyssey, Toyota Sienna, Ford Freestar/Taurus X. Key Features Vehicle Type: Minivan designed for passenger comfort and cargo versatility. Distinctive Features: Stow 'n Go seating (optional/standard across trims), abundant interior space, comfortable ride. 📋 Manual Details Coverage Areas Primary Coverage: North America, Europe (as Chrysler Voyager/Grand Voyager) Page Count Estimated Page Count: Over 2000 (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF due to file size) 📖 Manual Coverage Systems Covered Engine Mechanical: 2.8L CRD, 3.8L V6, 4.0L V6 engine overhauls, disassembly, assembly, torque specifications, component testing. Engine Electrical: Ignition system, fuel injection system (including Common Rail Diesel specifics), starting system, charging system, ECM/PCM operation, sensor diagnostics, wiring diagrams. Transmission Mechanical: 41TE automatic transmission overhaul, clutch pack replacement, torque converter, valve body diagnostics, gear train inspection. Transmission Electrical: Transmission Control Module (TCM) diagnostics, shift solenoids, speed sensors, range sensor, wiring schematics. Braking System: Front and rear brake inspection, rotor and pad replacement, caliper service, hydraulic system bleeding, ABS system diagnostics, parking brake. Suspension Steering: Front and rear suspension component inspection and replacement (struts, shocks, control arms, ball joints, tie rods), wheel alignment procedures, steering column, power steering system diagnostics. Body And Chassis: Body panel repair, door mechanisms, power sliding doors, liftgate, interior trim removal/installation, chassis component inspection. HVAC: Air conditioning system service, refrigerant charging, heater core replacement, climate control module diagnostics, blower motor. Electrical Systems: Lighting systems, power windows, power locks, power seats, sunroof, instrument cluster, body control module (BCM) diagnostics, fuse and relay identification, wiring diagrams. Safety Systems: Airbag system diagnostics, SRS module, seatbelt operation, tire pressure monitoring system (TPMS). Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, belt inspection/replacement. Diagnostics Troubleshooting: Step-by-step diagnostic procedures for common faults, fault code interpretation, symptom-based troubleshooting guides. Repair And Overhaul: Detailed procedures for component disassembly, inspection, repair, and reassembly for all major systems. Component Replacement: Instructions for replacing specific parts such as alternators, starters, water pumps, fuel pumps, sensors, etc. Recalibration And Programming: Information on recalibrating sensors and modules after replacement, though specific programming instructions might require dealer tools. Technical Depth Depth: Comprehensive; covers everything from basic fluid changes to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic trees. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) File Size: 150 MB Print Quality Resolution: High resolution, suitable for printing detailed diagrams and schematics. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Searchability Search Functionality: Likely searchable text (OCR processed) allowing quick access to specific topics and keywords. ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.8 L (2776 cc) Engine 1 Type: Common Rail Turbo Diesel (VM Motori A 428 DOHC) Engine 1 Power: Approx. 163 hp @ 3800 rpm Engine 1 Torque: Approx. 300-330 lb-ft @ 1800-2200 rpm Engine 1 Fuel System: Common Rail Direct Injection (CRDI) with turbocharger. Engine 2 Engine 2 Displacement: 3.8 L (3778 cc) Engine 2 Type: V6 SOHC Pentastar (later RT models may feature updated versions) Engine 2 Power: Approx. 197 hp @ 5000 rpm Engine 2 Torque: Approx. 250 lb-ft @ 3200 rpm Engine 2 Fuel System: Multi-port Fuel Injection (MPI). Engine 3 Engine 3 Displacement: 4.0 L (3952 cc) Engine 3 Type: V6 SOHC EGH Engine 3 Power: Approx. 251 hp @ 6000 rpm Engine 3 Torque: Approx. 259 lb-ft @ 4000 rpm Engine 3 Fuel System: Multi-port Fuel Injection (MPI). 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle Transmission Code: 41TE (likely used across 3.8L and potentially 2.8L diesel variants) Optional Transmission Type 2: 6-speed Automatic Transaxle (possibly for 4.0L V6 or specific export markets, check vehicle VIN) Features Transmission Features: Driver-adaptive electronic control, electronically modulated converter clutch, torque management. Fluid Specifications Transmission Fluid Type: Chrysler ATF+4 (or equivalent specification, e.g., Mopar ATF+4), consult manual for specific engine/transmission combinations. 📐 Dimensions Exterior Length: Approx. 203.5 inches (5169 mm) Width: Approx. 77.0 inches (1956 mm) (excluding mirrors) Height: Approx. 68.6 inches (1742 mm) Wheelbase: Approx. 121.6 inches (3089 mm) Cargo Cargo Volume Behind 3Rd Row: Approx. 32.0 cubic feet (0.9 cubic meters) Cargo Volume Behind 2Nd Row: Approx. 75.7 cubic feet (2.1 cubic meters) Cargo Volume Behind 1St Row: Approx. 140.0 cubic feet (4.0 cubic meters) Weights Curb Weight: Approx. 4500-4800 lbs (2041-2177 kg) depending on engine and trim. Gross Vehicle Weight Rating: Approx. 6200-6400 lbs (2812-2903 kg). 🛡️ Safety Features Ratings NHTSA Front Crash Test: 5-Star (for driver and passenger in frontal impact, typical for this...
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CHRYSLER Grand VOYAGER 2008-2013 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Grand Voyager
Generation:
RT Platform
Year Range:
2008-2013
Codes
Platform Code:
RT
👋 Introduction
Market Position
Segment:
Full-size Minivan
Target Audience:
Families, fleet operators, DIY mechanics, professional technicians.
Competitive Analysis
Key Competitors:
Dodge Grand Caravan (platform sharing), Honda Odyssey, Toyota Sienna, Ford Freestar/Taurus X.
Key Features
Vehicle Type:
Minivan designed for passenger comfort and cargo versatility.
Distinctive Features:
Stow 'n Go seating (optional/standard across trims), abundant interior space, comfortable ride.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America, Europe (as Chrysler Voyager/Grand Voyager)
Page Count
Estimated Page Count:
Over 2000 (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF due to file size)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
2.8L CRD, 3.8L V6, 4.0L V6 engine overhauls, disassembly, assembly, torque specifications, component testing.
Engine Electrical:
Ignition system, fuel injection system (including Common Rail Diesel specifics), starting system, charging system, ECM/PCM operation, sensor diagnostics, wiring diagrams.
Transmission Mechanical:
41TE automatic transmission overhaul, clutch pack replacement, torque converter, valve body diagnostics, gear train inspection.
Transmission Electrical:
Transmission Control Module (TCM) diagnostics, shift solenoids, speed sensors, range sensor, wiring schematics.
Braking System:
Front and rear brake inspection, rotor and pad replacement, caliper service, hydraulic system bleeding, ABS system diagnostics, parking brake.
Suspension Steering:
Front and rear suspension component inspection and replacement (struts, shocks, control arms, ball joints, tie rods), wheel alignment procedures, steering column, power steering system diagnostics.
Body And Chassis:
Body panel repair, door mechanisms, power sliding doors, liftgate, interior trim removal/installation, chassis component inspection.
HVAC:
Air conditioning system service, refrigerant charging, heater core replacement, climate control module diagnostics, blower motor.
Electrical Systems:
Lighting systems, power windows, power locks, power seats, sunroof, instrument cluster, body control module (BCM) diagnostics, fuse and relay identification, wiring diagrams.
Safety Systems:
Airbag system diagnostics, SRS module, seatbelt operation, tire pressure monitoring system (TPMS).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, belt inspection/replacement.
Diagnostics Troubleshooting:
Step-by-step diagnostic procedures for common faults, fault code interpretation, symptom-based troubleshooting guides.
Repair And Overhaul:
Detailed procedures for component disassembly, inspection, repair, and reassembly for all major systems.
Component Replacement:
Instructions for replacing specific parts such as alternators, starters, water pumps, fuel pumps, sensors, etc.
Recalibration And Programming:
Information on recalibrating sensors and modules after replacement, though specific programming instructions might require dealer tools.
Technical Depth
Depth:
Comprehensive; covers everything from basic fluid changes to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic trees.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
File Size:
150 MB
Print Quality
Resolution:
High resolution, suitable for printing detailed diagrams and schematics.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
Searchability
Search Functionality:
Likely searchable text (OCR processed) allowing quick access to specific topics and keywords.
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.8 L (2776 cc)
Engine 1 Type:
Common Rail Turbo Diesel (VM Motori A 428 DOHC)
Engine 1 Power:
Approx. 163 hp @ 3800 rpm
Engine 1 Torque:
Approx. 300-330 lb-ft @ 1800-2200 rpm
Engine 1 Fuel System:
Common Rail Direct Injection (CRDI) with turbocharger.
Engine 2
Engine 2 Displacement:
3.8 L (3778 cc)
Engine 2 Type:
V6 SOHC Pentastar (later RT models may feature updated versions)
Engine 2 Power:
Approx. 197 hp @ 5000 rpm
Engine 2 Torque:
Approx. 250 lb-ft @ 3200 rpm
Engine 2 Fuel System:
Multi-port Fuel Injection (MPI).
Engine 3
Engine 3 Displacement:
4.0 L (3952 cc)
Engine 3 Type:
V6 SOHC EGH
Engine 3 Power:
Approx. 251 hp @ 6000 rpm
Engine 3 Torque:
Approx. 259 lb-ft @ 4000 rpm
Engine 3 Fuel System:
Multi-port Fuel Injection (MPI).
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle
Transmission Code:
41TE (likely used across 3.8L and potentially 2.8L diesel variants)
Optional
Transmission Type 2:
6-speed Automatic Transaxle (possibly for 4.0L V6 or specific export markets, check vehicle VIN)
Features
Transmission Features:
Driver-adaptive electronic control, electronically modulated converter clutch, torque management.
Fluid Specifications
Transmission Fluid Type:
Chrysler ATF+4 (or equivalent specification, e.g., Mopar ATF+4), consult manual for specific engine/transmission combinations.
📐 Dimensions
Exterior
Length:
Approx. 203.5 inches (5169 mm)
Width:
Approx. 77.0 inches (1956 mm) (excluding mirrors)
Height:
Approx. 68.6 inches (1742 mm)
Wheelbase:
Approx. 121.6 inches (3089 mm)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 32.0 cubic feet (0.9 cubic meters)
Cargo Volume Behind 2Nd Row:
Approx. 75.7 cubic feet (2.1 cubic meters)
Cargo Volume Behind 1St Row:
Approx. 140.0 cubic feet (4.0 cubic meters)
Weights
Curb Weight:
Approx. 4500-4800 lbs (2041-2177 kg) depending on engine and trim.
Gross Vehicle Weight Rating:
Approx. 6200-6400 lbs (2812-2903 kg).
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star (for driver and passenger in frontal impact, typical for this generation).
NHTSA Side Crash Test:
4-Star (typical for side impact, varying by specific trim/options).
IIHS Ratings:
Good (in frontal offset crash tests, but often flagged for side impact performance depending on year and equipment).
Active Features
ABS:
Standard Anti-lock Braking System.
Traction Control:
Standard Traction Control System (TCS).
Electronic Stability Control:
Standard Electronic Stability Control (ESC) - likely branded as Electronic Stability Program (ESP).
Passive Features
Airbags:
Frontal airbags for driver and passenger, side curtain airbags (for all three rows), optional front side airbags.
Seat Belts:
3-point seat belts with pretensioners and load limiters for all seating positions.
💡 Technology Features
Infotainment
Infotainment System:
Uconnect infotainment system (various iterations depending on trim and year) with touchscreen, navigation (optional), rear-seat entertainment (optional).
Driver Assistance
Driver Assistance Features:
ParkView rear backup camera, ParkSense parking assist (rear and front optional), blind-spot monitoring (optional), rear cross-path detection (optional).
Connectivity
Connectivity Options:
Bluetooth streaming audio and hands-free calling, USB input, auxiliary audio input.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 to 8,000 miles (9,600 to 12,800 km) or 6 months, whichever comes first, using synthetic oil. Consult manual for specific engine.
Engine Air Filter Replacement:
Every 15,000 to 30,000 miles (24,000 to 48,000 km), depending on driving conditions.
Cabin Air Filter Replacement:
Every 15,000 to 20,000 miles (24,000 to 32,000 km).
Spark Plug Replacement Gasoline:
Typically 100,000 miles (160,000 km) for iridium-tipped plugs.
Transmission Fluid Change:
Every 60,000 to 100,000 miles (96,000 to 160,000 km), or as per severe duty schedule. Filter replacement recommended.
Fluid Specifications
Engine Oil Capacity 2.8L Crd:
Approx. 6.7 quarts (6.3 liters) with filter. Specific SAE grade (e.g., 5W-30) and API/ACEA specs required, consult manual.
Engine Oil Capacity 3.8L V6:
Approx. 4.5 quarts (4.3 liters) with filter. SAE 5W-20 is common.
Engine Oil Capacity 4.0L V6:
Approx. 4.5 quarts (4.3 liters) with filter. SAE 5W-20 is common.
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically orange or pink. Capacity approx. 10.0-11.5 quarts (9.5-10.9 liters).
Known Issues
Common Problem 1:
Power sliding door and liftgate actuator failures or wiring issues.
Common Problem 2:
Transmission solenoid pack failures or rough shifting (especially in the 41TE).
Common Problem 3:
2.8L CRD diesel specific: EGR valve issues, turbocharger problems, glow plug system faults.
Common Problem 4:
Water pump leaks and bearing failures.
Common Problem 5:
Suspension component wear (e.g., ball joints, tie rods, sway bar links).
📚 Vehicle History
Brand Heritage
Brand Focus:
Chrysler's long history in the minivan segment, beginning with the original Dodge Caravan and Plymouth Voyager in the 1980s.
Model Evolution
Third Generation Platform:
The RT platform represents the fifth generation of the minivan platform, introduced for the 2008 model year, with significant redesigns.
Regional Differences:
While sold as Chrysler Grand Voyager in many markets, it shared its platform with the Dodge Grand Caravan, with minor styling and feature variations.
Production
Assembly Location:
Windsor Assembly Plant, Ontario, Canada.
Production Years For Generation:
2008-2020 (with facelift in 2011 and introduction of Pentastar engines).
🏆 Awards & Recognition
Recognitions
Ward Top 10 Engines:
The 3.8L V6 engine was a frequent recipient of Ward's 10 Best Engines awards in earlier iterations, appreciated for its smoothness and refinement for its class.
Consumer Ratings:
Generally received mixed reviews from consumer organizations, often praised for practicality and value, but criticized for some interior material quality and long-term reliability concerns.
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