This manual covers the Chrysler Grand Voyager models produced between 2003 and 2007. As a full-size minivan, the Grand Voyager was engineered for family transport, offering versatile cargo and passenger hauling capabilities and comfort for long-distance travel. Building on Chrysler's pioneering legacy in the minivan segment, this generation of the Grand Voyager, part of the RT platform, featured an updated, more aerodynamic design and often revised powertrains. It typically offered seating for seven or eight passengers and was commonly equipped with 3.3L or 3.8L V6 engines paired with a 4-speed automatic transmission.
This comprehensive factory service manual provides detailed, factory-level information essential for maintaining and repairing your Chrysler Grand Voyager. It covers all styles and configurations for the specified model years, offering step-by-step repair procedures, diagnostic guides, and troubleshooting information for all major vehicle systems. These systems include the engine, transmission, brakes, suspension, steering, electrical components, HVAC, body, and interior. The manual also details general maintenance, lubrication, and includes crucial safety guidelines, wiring diagrams, and detailed illustrations to assist owners, mechanics, and technicians in keeping the vehicle in optimal condition.
Years Covered:
2003, 2004, 2005, 2006, 2007
Generation Code:
RT Platform (North American Market: Dodge Grand Caravan/Chrysler Town & Country, European Market: Chrysler Voyager/Grand Voyager)
Vehicle Segment:
Full-size Minivan
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Venture/Uplander, Nissan Quest
Vehicle Purpose:
Family transport, versatile cargo and passenger hauling, long-distance travel comfort.
Cost Savings:
Enables DIY servicing, potentially saving $50-$60 per hour on labor costs.
Usability Features:
Searchable PDF, printable pages, detailed illustrations, diagrams, photos, step-by-step instructions, notes, cautions, warnings.
Source Authenticity:
Actual Genuine Factory Repair Manuals, not third-party content.
Vehicle Coverage:
All styles and configurations of Chrysler Grand Voyager for model years 2003-2007
Estimated Page Count:
Hundreds of pages (specific number not provided, but described as 'complete')
Type:
Factory Service Manual / Repair Manual
Delivery Method:
Immediate download link provided after purchase.
Engine:
Engine Service/Repair, Engine Control System, Fuel Injection/Fuel System, Emission System, Cooling System
Transmission:
Transmission Service/Repair, Differential/Drive, Axle
Steering Suspension:
Suspension, Steering
Electrical HVAC:
Wiring Diagram, Electrical System, Heater/Air Conditioner
Body Interior Safety:
Chassis/Body, Interior, Restraint System
Electrical Diagrams:
Includes detailed wiring diagrams for ease of diagnosing and repairing the electrical system.
Maintenance And Troubleshooting:
General Maintenance, Troubleshooting, Periodic Lubrication
Repair And Rebuild:
Step-by-step repair procedures for all systems, rebuild procedures, diagnostics
Diagnostic Procedures:
Includes advanced troubleshooting guides to diagnose and correct problems, likely referencing Diagnostic Trouble Codes (DTCs) and diagnostic procedures for various electronic modules.
Depth Of Information:
Comprehensive factory-level detail, suitable for professional technicians and knowledgeable owners, covering everything from basic maintenance to complete restoration.
Instructional Style:
Detailed substeps, numbered instructions, notes, cautions, and warnings throughout.
Visual Aids:
Detailed illustrations, drawings, and photos; enlarged insets for detailed part examination.
Software Requirements:
Adobe PDF Reader
Printability:
Fully printable (individual pages, chapters, or entire manual)
Binding:
Digital Download (intended for printing and binding by user)
Paper Type:
N/A (Digital)
Engine Options:
Typically featured the 3.3L and 3.8L V6 engines (e.g., EGH and EGQ series). Specific engine codes for the European Grand Voyager may differ (e.g., 2.8L CRD Diesel).
Horsepower Torque Range:
3.3L V6: ~180-185 hp; 3.8L V6: ~200-215 hp. Torque figures vary accordingly. (Specific values depend on exact engine and year).
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Engine Management:
Engine Control Module (ECM) for managing fuel injection, ignition timing, emissions, and other engine functions.
Type:
4-speed Automatic Transmission (e.g., 41TE, 42LE/42RLE)
Type:
Diesel models in European markets often paired with manual or different automatic transmissions.
Transmission Control:
Electronically controlled, with Overdrive (OD) functionality.
Length:
Approximately 201 inches (dependent on specific configuration)
Width:
Approximately 79 inches
Height:
Approximately 69 inches
Curb Weight Range:
Approximately 4,300 - 4,700 lbs (Varies by engine and trim)
Seating Capacity:
Typically 7 or 8 passengers depending on configuration.
NHTSA Ratings:
Generally good for its era, though specific model year ratings vary. Frontal impact ratings often 4 or 5 stars, side impact varied.
ABS Traction Control:
Anti-lock Braking System (ABS) standard, Traction Control (TCS) available on some trims/years.
Airbags:
Standard front airbags. Optional side-impact airbags for front and sometimes second-row occupants.
Seat Belts:
Three-point seat belts for all seating positions, with pretensioners for front seats.
Audio Systems:
Factory AM/FM/CD players, optional CD/MP3 players, available rear-seat entertainment systems (DVD players).
Cruise Control:
Standard cruise control.
Parking Assistance:
Rear parking assist sensors available on some higher trims.
Power Features:
Power windows, power door locks, available power sliding doors and power liftgate.
Oil Change Interval:
Typically 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Refer to manual for specific recommendations.
Transmission Service Interval:
Check fluid level and condition regularly; fluid and filter change recommended every 30,000-60,000 miles, or as specified in the manual.
Engine Oil:
SAE 5W-30 or 5W-20 synthetic blend or full synthetic, meeting Chrysler MS-6395 specification. (Verify with manual for exact spec).
Transmission Fluid:
ATF+4 (Chrysler Specification MS-9602 or equivalent). Capacity approx. 3-4 quarts for a fluid change.
Coolant:
Mopar HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant (Orange).
Common Problems:
Transmission issues (torque converter shudder, solenoid pack failure), power steering pump leaks, HVAC blower motor resistor failures, rear liftgate struts weakening, interior trim wear, EGR valve issues on some gasoline engines.
Common Maintenance Items:
Regular replacement of spark plugs, serpentine belt, fuel filter, cabin air filter, and coolant.
Filter Part Numbers:
Oil Filter: e.g., Mopar MO-899 or equivalent Wix/Fram. Air Filter: e.g., Mopar P5251148 or equivalent. Cabin Air Filter: e.g., Mopar 5058372AA or equivalent.
Chrysler Minivan Legacy:
Chrysler is credited with inventing the modern minivan segment in the early 1980s with the Dodge Caravan/Plymouth Voyager, setting a benchmark for practicality and family transport.
Third Generation Changes:
The 2001 redesign (which encompasses the 2003-2007 models) featured a more aerodynamic design, significantly updated interior, improved safety, and often revised powertrains compared to earlier generations. This generation also saw the introduction of Stow 'n Go seating in later years (though availability for Grand Voyager specific to European markets needs confirmation, it was a hallmark of the platform).
Production Location:
Primarily Windsor, Ontario, Canada.
Consumer Ratings:
Consistently ranked well for practicality, interior space, and family-friendliness by automotive publications during its production run.
