Target Audience:
Families, individuals requiring substantial passenger and cargo capacity.
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Dodge Grand Caravan.
Vehicle Attributes:
Spacious interior, flexible seating arrangements, available Stow 'n Go seating (though primarily associated with later generations/different models), family-oriented features, practical for hauling cargo and passengers.
Purpose:
To provide detailed, accurate, and official repair and maintenance guidance for the Chrysler Voyager (RS platform) from 2003 to 2007.
Powertrain:
Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Transmission (Automatic)
Chassis:
Suspension (Front & Rear), Steering System, Brake System (Front & Rear, ABS), Wheels & Tires
Electrical:
Body Electrical Systems, Lighting, Instrumentation, HVAC (Heating, Ventilation, Air Conditioning), Audio System, Power Accessories (Windows, Locks, Seats)
Body:
Body Structure, Exterior Panels, Doors, Hood, Liftgate, Interior Trim, Glass, Seals
Diagnostics:
Diagnostic Trouble Codes (DTCs), Diagnostic Procedures, Component Testing, Electrical Schematics, Wiring Diagrams
Maintenance:
Scheduled Maintenance, Fluid Changes (Engine Oil, Coolant, Transmission Fluid, Brake Fluid, Power Steering Fluid), Filter Replacements (Oil, Air, Cabin), Spark Plug Replacement, Belt Inspection/Replacement
Repair:
Engine Overhaul, Transmission Overhaul, Suspension Component Replacement, Brake Service, Steering Component Repair, Electrical Component Diagnosis and Replacement, Body Panel Repair/Replacement
Troubleshooting:
Systematic Diagnosis of Common Problems, Symptom-Based Troubleshooting Guides, Component Testing Procedures
Technical Data:
Specifications, Tolerances, Torque Values, Diagnostic Charts, Wiring Diagrams
Electrical Diagnostics:
Includes detailed wiring diagrams, component location charts, and diagnostic flowcharts for all electrical systems, crucial for troubleshooting issues with power windows, locks, infotainment, and more.
Engine Mechanical Repair:
Covers cylinder head removal/installation, piston and connecting rod service, crankshaft replacement, valve train adjustments, and complete engine assembly/disassembly procedures.
Brake System Service:
Detailed instructions for brake pad and rotor replacement, caliper service, bleeding the brake system, ABS component diagnosis, and parking brake adjustment.
Depth:
Comprehensive - Covers basic maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics and body repair.
Diagnostic Tools:
References diagnostic trouble codes (DTCs) and outlines procedures for using factory-level diagnostic scan tools (e.g., DRB III or equivalent).
Format Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing for quick information retrieval.
Quality:
High-resolution digital scans of original factory documentation, suitable for printing.
Binding:
N/A (Digital Download - user prints and binds)
Paper Recommendation:
Standard copier paper or heavier cardstock for cover pages, depending on user preference.
Engine 1:
3.3L (3301cc) OHV V6, 12-valve
Engine 1 Horsepower:
Approx. 170-180 hp @ 5000-5200 rpm (depending on year and specific configuration)
Engine 1 Torque:
Approx. 200-210 lb-ft @ 3200-3400 rpm (depending on year and specific configuration)
Engine 2:
3.8L (3778cc) OHV V6, 12-valve
Engine 2 Horsepower:
Approx. 180-215 hp @ 5000-5200 rpm (depending on year and specific configuration)
Engine 2 Torque:
Approx. 230-250 lb-ft @ 3200-3800 rpm (depending on year and specific configuration)
Fuel Delivery:
Multi-Port Fuel Injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline
ECU System:
Chrysler's proprietary engine control unit (ECU) architecture, likely related to the NGC (Next Generation Controller) or similar systems of the era.
NHTSA Rollover Resistance:
3/5 Stars (typical for SUVs/minivans of this era, varies slightly by model year)
IIHS Crash Test:
Good in front crash ratings (typical for this generation).
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS)
Airbags:
Driver and front passenger airbags, optional front side-impact airbags.
Seat Belts:
All seating positions equipped with three-point seat belts, front pretensioners.
Audio System:
Factory AM/FM/CD player, optional premium audio systems with amplifier and subwoofer. Available in-dash navigation on higher trims for later years.
Cruise Control:
Standard cruise control.
Parking Sensors:
Optional rear park assist system.
Power Accessories:
Power windows, power door locks, power sliding doors (optional), power liftgate (optional).
HVAC:
Manual or automatic climate control, dual-zone climate control, rear auxiliary climate control.
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Consult the manual for specific recommendations.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles, or as specified by the manual, particularly for severe driving conditions.
Coolant Change:
Initial change at 100,000 miles, then every 50,000 miles thereafter (using HOAT coolant).
Spark Plugs:
Typically every 60,000-100,000 miles, depending on plug type (e.g., platinum or iridium).
Engine Oil Type:
SAE 5W-30, meeting Chrysler MS-6395 specification.
Coolant Type:
Chrysler Formula 10W-30 (HOAT - Hybrid Organic Acid Technology) or equivalent.
Power Steering Fluid:
Chrysler power steering fluid or ATF+4.
Common Problems:
Transmission solenoid/relay failures, EGR valve issues, power door lock actuators, rear suspension sag, brake component wear, minor electrical gremlins.
Diagnostic Tips:
The manual provides systematic diagnostic procedures to pinpoint the root cause of these common issues.
