🏷️ Basic Information

Make:

Chrysler

Model:

Voyager / Town & Country / Caravan / Grand Voyager

Years Covered:

2001, 2002, 2003, 2004, 2005, 2006, 2007

Chassis Code:

RS (Third Generation Facelift)

👋 Introduction

Vehicle Class:

Minivan

Target Demographic:

Families and individuals requiring flexible cargo and passenger capacity.

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Nissan Quest, Chevrolet Venture/Montana.

Vehicle Strengths:

Spacious interior, versatile seating configurations (Stow 'n Go introduced later, but flexible seating was a hallmark), comfortable ride, available all-wheel drive (on some models), long wheelbase options for maximum space.

📋 Manual Details

General Coverage:

Comprehensive service, repair, and maintenance for all major vehicle systems.

Regions Covered:

North America (USA, Canada, Mexico) and potentially international variants, as indicated by model names.

Estimated Page Count:

Over 2000 pages (typical for full workshop manuals of this era and scope).

Type:

Workshop Service and Repair Manual

Language:

English

Format:

Digital (likely PDF, given file size and common distribution).

📖 Manual Coverage

Engine Mechanical:

Engine construction, cylinder head, valve train, pistons, crankshaft, connecting rods, lubrication system, cooling system, fuel delivery, intake and exhaust manifolds, timing components.

Engine Electrical:

Ignition system, starting system, charging system, ECU (Engine Control Unit) diagnostics, sensors, actuators, emissions control systems (OBD-II).

Transmission Manual:

Manual transmission (if applicable for specific trims), clutch system, shift linkage, gear oil specifications.

Transmission Automatic:

Automatic transmission (41TE/42LE, 45RFE), hydraulic control systems, torque converter, electronic controls, shift solenoids, transmission fluid type and capacity.

Brakes:

Front and rear brake systems, hydraulic lines, master cylinder, brake booster, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), parking brake, rotor and pad replacement, bleeding procedures.

Suspension:

Front suspension (MacPherson strut, lower control arm), rear suspension (solid axle, leaf springs or coil springs depending on model/trim), shock absorbers, springs, bushings, wheel bearings, alignment specifications.

Steering:

Power steering system, steering rack or gearbox, power steering pump, fluid type, steering column, wheel alignment.

Electrical Body:

Wiring diagrams, lighting (headlights, taillights, interior), power windows, power door locks, power sliding doors, power liftgate, horn, wipers, washers, mirrors, power seats, interior controls, fuses, relays.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, blower motor, heater core, evaporator, condenser, refrigerant type (R-134a), charge capacity, troubleshooting.

Body Interior:

Interior trim removal and installation, dashboard, door panels, seating, cargo area, headliner, body panels, bumpers, glass, seals.

Body Exterior:

Body panel repair, door replacement, fender replacement, hood, tailgate, bumpers, mirrors, trim pieces, rust prevention, chassis and frame.

Restraint Systems:

Airbag system (SRS - Supplemental Restraint System), seat belts, pretensioners, diagnostic procedures for airbag faults.

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), fluid checks and top-offs, spark plug replacement, belt inspection and replacement, tire rotation.

Engine Repair:

Complete engine overhaul, cylinder head gasket replacement, piston and ring replacement, bearing replacement, timing belt/chain service, water pump replacement, oil pan gasket replacement.

Transmission Service:

Automatic transmission fluid and filter change, manual transmission fluid change, clutch replacement, transmission overhaul procedures.

Brake Repair:

Brake pad and rotor replacement, caliper overhaul, brake line replacement, brake bleeding, ABS component replacement and testing.

Suspension Steering Repair:

Strut and shock absorber replacement, ball joint replacement, tie rod end replacement, power steering pump and rack replacement, wheel alignment adjustments.

Electrical Diagnostics:

Troubleshooting electrical circuits using wiring diagrams, testing sensors and actuators, diagnosing computer control modules, fuse and relay testing.

HVAC Service:

Refrigerant evacuation and recharge, component replacement (compressor, condenser, evaporator), leak detection, blower motor replacement.

Body Work:

Body panel alignment, door hinge adjustment, glass replacement, seal replacement, minor dent repair procedures.

Troubleshooting Guides:

Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems.

Diagnostic Codes:

P-codes, B-codes, C-codes, U-codes, and their associated descriptions and diagnostic steps.

Depth:

Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls and complex electrical diagnostics.

Target Audience:

Professional automotive technicians and experienced DIY enthusiasts.

📊 Manual Specifications

Format Details:

Likely PDF. Searchable text functionality is highly probable. High-resolution scans for clarity.

Quality:

Designed for clear reproduction if printed. Contains diagrams, schematics, and photographs.

Binding For Digital:

N/A (Digital format).

Paper For Digital:

N/A (Digital format).

Size In Mb:

174 MB

⚙️ Engine Specifications

Engine 2 4L Edz I4:

2.4L EDZ Inline-4. Power: Approx. 150-156 hp. Torque: Approx. 160-165 lb-ft. Known for reliability but less power than V6. Often paired with automatic transmissions.

Engine 3 3L Ega V6:

3.3L EGA/EGH V6. Power: Approx. 180-182 hp. Torque: Approx. 200-205 lb-ft. Common and generally reliable, offering a good balance of power and efficiency for the vehicle's size.

Engine 3 8L L32 V6:

3.8L L32/L67 V6 (Supercharged option on some Grand Voyager models, especially outside North America, but less common in US Caravan/Town & Country). Power: Approx. 200-215 hp (naturally aspirated) or 230-240 hp (supercharged). EGH V6 is generally more prevalent for US models in this generation.

Acceleration 0 60 Mph:

Approximately 9-10 seconds for V6 models, 10-11 seconds for 4-cylinder models (vehicle dependent).

Fuel Type:

Unleaded Gasoline

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI).

Recommended Octane:

87 AKI (for standard V6 and I4), 89 AKI may be recommended for improved performance on some V6 variants.

🔧 Transmission

Automatic Transmission Standard:

4-speed automatic (e.g., 41TE/42LE/45RFE) was standard on most V6 and many I4 models.

Manual Transmission Optional:

Less common, likely available on base models or specific international markets. If present, typically a 5-speed manual.

All Wheel Drive:

Available as an option on certain trims, particularly with the V6 engines.

Transmission Fluid Spec V6 Auto:

Chrysler ATF+4 (Mopar Material Standard MS-9602) or equivalent.

Transmission Fluid Capacity V6 Auto:

Approximately 4 quarts (3.8 liters) for a pan drop and filter change; higher for a full flush.

📐 Dimensions

Wheelbase Standard:

Approx. 119.3 inches (3030 mm)

Wheelbase Long:

Approx. 119.3 inches (3030 mm) for Caravan/Voyager, 124.9 inches (3172 mm) for Grand Caravan/Grand Voyager.

Length:

Varies by wheelbase, e.g., ~190 inches (standard) to ~201 inches (long).

Width:

Approx. 72 inches (1829 mm).

Height:

Approx. 68-70 inches (1727-1778 mm).

Max Cargo Volume:

Over 150 cubic feet (with rear seats removed/folded, depending on configuration).

Curb Weight:

Approx. 3,800 - 4,200 lbs (1724 - 1905 kg), depending on engine and configuration.

Gross Vehicle Weight Rating Gvwr:

Approx. 5,300 - 5,600 lbs (2404 - 2540 kg).

🛡️ Safety Features

NHTSA Front Impact Driver:

Likely 4-star (out of 5) for the 2001-2007 generation, but specific ratings can vary slightly by year and testing protocol.

NHTSA Front Impact Passenger:

Likely 4-star (out of 5).

IIHS Crash Test Results:

Generally rated 'Good' in frontal offset tests from the IIHS for this era, though side impact performance could be more variable.

ABS:

Standard Anti-lock Braking System (ABS) on most models, often with Electronic Brake-force Distribution (EBD).

Traction Control:

Optional or standard on higher trims; Traction Control System (TCS).

Stability Control:

Electronic Stability Control (ESC) became more common and potentially available on later models in this range, though not universally standard.

Airbags:

Standard front driver and passenger airbags. Optional side curtain airbags or side-impact airbags on some models.

Seatbelts:

Three-point seat belts for all seating positions, with pretensioners for front seats.

💡 Technology Features

Audio Systems:

Available with AM/FM stereo, CD player, cassette player, and optional premium audio systems with more speakers. Rear-seat entertainment systems (DVD players) were also available on higher trims.

Navigation:

Optional in-dash navigation systems were available on premium models in later years of this generation.

Parking Sensors:

Optional rear parking assist sensors could be fitted to aid in maneuvering.

Power Features:

Power windows, power door locks, power mirrors, power adjustable pedals (on some models), and power sliding doors were widely available across trims.

🔧 Maintenance

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first, with synthetic blend oil. Conventional oil may require 5,000 miles (8,000 km) intervals.

Air Filter Replacement:

Check every 15,000 miles (24,000 km), replace as needed, typically around 30,000 miles (48,000 km).

Cabin Air Filter Replacement:

Recommended every 15,000 - 20,000 miles (24,000 - 32,000 km) or annually.

Spark Plug Replacement:

Iridium spark plugs typically last up to 100,000 miles (160,000 km). Check manual for exact type and interval.

Transmission Fluid Service:

Inspect every 30,000 miles (48,000 km), change fluid and filter every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on driving conditions. ATF+4 is a 'fill for life' fluid if maintained correctly, but fluid change is recommended.

Engine Oil Type:

SAE 5W-30 (API certified for SN or newer). Check owner's manual for specific viscosity and API service category.

Engine Oil Capacity V6:

Approx. 4.5 quarts (4.3 liters) with filter.

Engine Oil Capacity I4:

Approx. 4.0 quarts (3.8 liters) with filter.

Coolant Type:

Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) antifreeze, typically a pink color. Mopar 5-Year/100,000 Mile Formula or equivalent.

Power Steering Fluid:

ATF+4 (Chrysler Specification MS-9602) or Pentastar Power Steering Fluid.

Transmission Slipping:

Certain automatic transmission variants (like the 41TE/42LE) could experience issues with solenoid pack failure, torque converter shudder, or internal seal leaks, especially with higher mileage. Regular fluid changes are critical.

Engine Oil Sludge:

If oil changes are neglected, sludge can build up, particularly in the 3.3L and 3.8L V6 engines, leading to lubrication issues. Adhering to the recommended maintenance schedule is vital.

Power Sliding Doors:

The electric motors and mechanisms for power sliding doors and liftgates can wear out, leading to slow operation or failure. Lubrication and adjustment are key.

Suspension Components:

Worn ball joints, tie rod ends, and sway bar links are common wear items due to the vehicle's weight and typical use. Symptoms include clunking noises and vague steering.

HVAC Blend Doors:

Blend door actuators can fail, leading to improper air temperature control or no airflow from certain vents.

📚 Vehicle History

Chrysler Minivan Legacy:

Chrysler invented the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983. This lineage established the brand as a leader in this vehicle category.

Third Generation Facelift:

The 2001 model year marked a significant refresh for the third generation (RS platform). Key changes included updated styling, interior, and the introduction of new powertrain options and features like power sliding doors and entertainment systems.

Name Strategy:

Chrysler offered the minivan under multiple brand names: Chrysler Voyager (base models, often international), Chrysler Town & Country (premium trim), Dodge Caravan (value-oriented), and Grand Caravan (long wheelbase). Plymouth Voyager was phased out during this generation.

Manufacturing Locations:

Primarily Windsor, Ontario, Canada. Other plants may have been involved in assembly or component production.

Production End Of Generation:

This generation (RS) ran from 1996 to 2007, with significant updates in 2001 and further refinements until the introduction of the RT platform.

🏆 Awards & Recognition

Car And Driver 10Best:

The Dodge Caravan and Plymouth Voyager were frequent recipients of Car and Driver's 10Best list in their earlier generations, cementing their status as segment leaders.

Consumer Satisfaction Ratings:

While specific ratings vary, Chrysler minivans of this era generally performed well in initial quality surveys but could see a decline in long-term dependability compared to some Asian competitors, particularly concerning transmission and electrical components.