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Chrysler
Chrysler Voyager 2003-2007 Service Repair Workshop Manual
Chrysler Voyager 2003-2007 Service Repair Workshop Manual
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$16.99
Preço normal
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$16.99
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Vehicle data plateRef 74798
- Brand
- Chrysler
- Vehicle
- Marine
- Models covered
- Misc, Outboard Engines, Voyager
- Years
- 2003, 2004, 2005, 2006, 2007
- Format
- PDF, searchable, print-ready
- Delivery
- Instant download after checkout
- Language
- English
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What happens after you pay
- Download link opens on the order page immediately
- The same link is emailed to you — re-download any time
- Open on phone, tablet or PC; print only the pages you need
- Not sure it covers your model year? Ask us before you buy
| 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. |
Delivery & file format
Delivery & file format
This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.
Check the model year and engine before you buy
Check the model year and engine before you buy
Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.
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Chrysler Voyager 2003-2007 Service Repair Workshop Manual
Chrysler / Car · PDF · Instant download
$16.99
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