🏷️ Basic Information

Make:

Dodge

Model:

Voyager

Year Range Covered:

2003-2007

Chassis Code:

NS (for North America), PG (for Europe)

👋 Introduction

Market Segment:

Minivan

Key Competitors:

Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture, Plymouth Voyager (pre-2001 sharing platform), Kia Sedona.

Versatility:

Known for its spacious interior, flexible seating configurations, and practical hauling capabilities, making it a popular choice for families.

Usability:

User-friendly PDF format with interactive navigation and searchability, allowing users to print only necessary pages, avoiding traditional greasy paper manuals.

Audience:

DIY enthusiasts, independent repair shops, owners seeking to maintain and repair their Dodge Voyager.

📋 Manual Details

Regions Covered:

North America, Europe (specific variations may apply)

Estimated Page Count:

1500+

Type:

Service and Repair Manual (Workshop Manual)

Language:

English

Format:

Electronic (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, piston and connecting rod, crankshaft and main bearings, timing system, lubrication system, cooling system, fuel system (carbureted/injection), exhaust system.

Engine Management:

Ignition system, fuel injection control, emissions control systems (EGR, PCV), sensors and actuators, diagnostic trouble codes (DTCs), powertrain control module (PCM).

Transmission Manual:

Clutch system, manual transmission (gearbox) overhaul, shifting mechanisms, driveshafts.

Transmission Automatic:

Automatic transmission (transaxle) overhaul, hydraulic control system, torque converter, transmission fluid cooling, electronic shift control.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, power assist (booster), ABS (Anti-lock Braking System) diagnosis and repair, parking brake.

Suspension Steering:

Front and rear suspension components (struts, shocks, control arms, bushings), steering system (rack and pinion, power steering), wheel alignment specifications.

Electrical System:

Battery, charging system (alternator, starter), lighting system, horn, wipers, power windows, power locks, instrument cluster, body control module (BCM), fuse and relay identification and testing.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, diagnosis and repair of A/C compressor, condenser, evaporator, blower motor, climate controls.

Body And Chassis:

Body panels, doors, hood, liftgate, interior trim, chassis lubrication, rust proofing, collision repair information.

Safety Systems:

Airbag system diagnosis and repair, seatbelt mechanisms.

Maintenance:

Routine scheduled maintenance (oil changes, filter replacements, spark plugs, belts, hoses), fluid checks and changes, tire rotation and inspection.

Troubleshooting:

Systematic diagnostic procedures for common and complex issues, using diagnostic trouble codes (DTCs), symptom-based troubleshooting guides.

Repair:

Step-by-step instructions for component removal, installation, and repair across all covered systems, including engine rebuilds, transmission overhauls, brake service, suspension work, and electrical component replacement.

Diagnostics:

Detailed diagnostic flowcharts, wiring diagrams, component testing procedures, specifications for electrical signals and pressures.

Depth:

Comprehensive, covering everything from basic fluid changes and inspections to complete engine and transmission rebuilds, complex electrical diagnostics, and body repair.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Printability:

High-quality, printable pages for individual section printing.

Binding Type:

N/A (Electronic Format)

Paper Type:

N/A (Electronic Format)

Interactivity:

Interactive with easy subject/link navigation system, searchable text.

⚙️ Engine Specifications

Engine Code Gasoline Northamerica:

EDZ (3.3L V6 OHV 12-valve)

Engine Code Gasoline Northamerica Optional:

EGW (3.8L V6 OHV 12-valve)

Engine Code Diesel Europe:

2.5 CRD (VM Motori turbodiesel)

Horsepower 3.3L:

Approx. 180 hp @ 5000 rpm

Torque 3.3L:

Approx. 210 lb-ft @ 3200 rpm

Horsepower 3.8L:

Approx. 190-200 hp @ 4800-5000 rpm

Torque 3.8L:

Approx. 230-235 lb-ft @ 3400-3600 rpm

Horsepower 2.5 Crd:

Approx. 116 hp @ 4000 rpm

Torque 2.5 Crd:

Approx. 214 lb-ft @ 1800 rpm

Fuel System Gasoline:

Multi-port fuel injection (MPI)

Fuel System Diesel:

Common Rail Direct Injection (CRD)

Fuel Type Gasoline:

Unleaded gasoline (87 octane recommended)

Fuel Type Diesel:

Diesel fuel

🔧 Transmission

Transmission Type Standard Na:

4-speed automatic (42LE)

Transmission Type Optional Na:

N/A (Only 4-speed automatic offered in North America for these years)

Transmission Type Standard Eu:

4-speed automatic (41TE/42LE) or 5-speed manual ( Getrag)

Automatic Transmission Features:

Electronic overdrive, torque converter lock-up.

📐 Dimensions

Length:

Approx. 189.8 inches (4820 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 69.0 inches (1753 mm)

Wheelbase:

Approx. 112.1 inches (2847 mm)

Seating Capacity:

7 passengers (2-2-3 configuration typical)

Cargo Behind 3Rd Row:

Approx. 15.0-21.0 cu ft (depending on configuration)

Cargo Behind 2Nd Row:

Approx. 70.0-80.0 cu ft

Cargo Behind 1St Row:

Approx. 140.0-160.0 cu ft

Curb Weight:

Approx. 4000-4300 lbs (1814-1950 kg)

Gross Vehicle Weight Rating:

Approx. 5500-5700 lbs (2495-2585 kg)

🛡️ Safety Features

NHTSA Driver Frontal Impact:

Generally good to excellent (4 or 5 stars)

NHTSA Passenger Frontal Impact:

Generally good to excellent (4 or 5 stars)

NHTSA Side Impact Front:

Mixed, can vary by year and specific test (3 or 4 stars common)

NHTSA Side Impact Rear:

Mixed, can vary (3 or 4 stars common)

ABS:

Standard on most models

Traction Control:

Available on some models, particularly with higher engine options

Airbags Front:

Driver and front passenger airbags standard

Airbags Side:

Optional side-curtain airbags available on some later models

Seatbelts:

3-point seatbelts for all seating positions, front seatbelt pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional cassette player, CD changer, and premium Infinity speaker systems were available.

Rear Entertainment:

Optional rear-seat entertainment system with a VCR or DVD player and flip-down screen was available on higher trims.

Cruise Control:

Standard on most models.

Rear Parking Assist:

Optional park assist sensors were available on some models.

Keyless Entry:

Available on most trims.

Remote Start:

Optional remote start system was available.

🔧 Maintenance

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (synthetic oil recommended for extended intervals).

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Spark Plug Replacement 3.3L/3.8L:

Every 100,000 miles (160,000 km) with iridium-tipped plugs.

Transmission Fluid Change:

Every 60,000 miles (96,000 km) or 4 years, whichever comes first.

Engine Oil Type 3.3L/3.8L:

SAE 5W-30, API SN or newer, synthetic blend or full synthetic recommended.

Engine Oil Capacity 3.3L:

Approx. 4.5 quarts (4.3 liters) with filter change.

Engine Oil Capacity 3.8L:

Approx. 4.5 quarts (4.3 liters) with filter change.

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity Automatic:

Approx. 4.2 quarts (4.0 liters) for a drain and fill, 10.0-11.0 quarts (9.5-10.4 liters) for a complete overhaul.

Coolant Type:

HOAT (Hybrid Organic Acid Technology) - Mopar Antifreeze/Coolant, 5 year/100,000 mile formula, or equivalent.

Power Steering Fluid:

Mopar Power Steering Fluid or ATF+4.

Transmission Reliability:

Some models, particularly early 42LE transmissions, can experience issues with torque converter shudder, solenoid failure, or internal wear if not properly maintained. Fluid changes are critical.

Engine Misfires:

Can occur due to failing ignition coils, spark plug wires, or clogged fuel injectors, especially in the 3.3L and 3.8L V6 engines.

Power Door Locks Windows:

Actuator failures, wiring harness issues in door panels are common.

Cv Joints:

Wear and tear on front CV joints and boots can lead to clicking noises during turns.

Alternator Failure:

Alternators have a typical lifespan and can fail, leading to charging system problems.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge (and its sibling Plymouth Voyager) pioneered the modern minivan segment in the early 1980s, setting benchmarks for space and versatility.

Generation:

This generation (2001-2007) is often referred to as the RS/GS platform, representing a significant redesign from previous generations, with improved safety, styling, and powertrain options.

Manufacturing Location:

Windsor, Ontario, Canada (primarily); Saltillo, Mexico (for some variants)

Production Period:

The Dodge Voyager (North American version) was produced from 1984 to 2003. The European-market Voyager continued until 2007, and the North American market Dodge Grand Caravan filled the minivan role, but this manual specifically covers the Voyager model from 2003-2007, which largely corresponds to the European market model based on the NS platform.

🏆 Awards & Recognition

Family Car Awards:

While specific awards for the 2003-2007 Voyager model are less frequently cited compared to its predecessors or competitors like the Odyssey or Sienna, the Dodge minivan platform consistently received accolades for its practicality, interior space, and innovative seating solutions throughout its lineage.

IIHS Ratings:

The Insurance Institute for Highway Safety (IIHS) ratings varied by year and test. Early models in this generation typically received 'Acceptable' or 'Good' ratings for frontal impacts. Side impact ratings were generally less strong compared to contemporary vehicles designed with more advanced side-impact protection.