Description

Daimlerchrysler Caravan, Grand Caravan, Town & Country, Voyager, Grand Voyager Technical Manual

You have a Caravan, a Town & Country, or a Voyager on the lift. The customer needs a parking brake cable, a front stabilizer bar, or a fog light kit. The aftermarket parts catalog throws you a generic part number that doesn’t match the VIN. That wastes your time and their money.

This Daimlerchrysler Caravan, Grand Caravan, Town & Country, Voyager, Grand Voyager Technical Manual is the factory parts documentation that DaimlerChrysler engineers used. 634 pages of OEM-verified part numbers, VIN plate decoding, and component diagrams. No guesswork. You decode the VIN, find the right group, order the exact Mopar part. I’ve seen too many guys order a “compatible” stabilizer bar that has the wrong bushing diameter. This manual fixes that.

VIN Plate Decoding: The First Step

Every job starts with the VIN. The manual opens with a full VIN plate decoding table. Position 4 tells you GVWR range in pounds (1815–3175 kg). Position 5 decodes vehicle line – Caravan, Grand Caravan, Town & Country, Voyager, Grand Voyager – including FWD vs AWD. Position 6 lists series like LX, SE, Sport, ES, Limited, EX, EL. You need that to order the correct rear disc brake assembly (Fig. 4-140) or the right water pump for a 2.4L EDZ versus a 3.8L EGM. The table on page 1 lays it all out. Without it, you’re guessing.

Brake System Parts: Factory Specs vs Aftermarket

Group 5 covers service brakes front and rear, power brake booster, master cylinder, lines and hoses, and brake pedals. The manual shows separate figures for drum vs disc rear brakes – Fig. 5-210 and Fig. 5-220. It also distinguishes chassis lines for short wheel base (SWB) and long wheel base with or without [CYC] – Fig. 5-530 to 5-550. If you need a rear parking brake cable, Group 4 lists two variants: without [CYC] (Fig. 4-120) and with [CYC] (Fig. 4-130). You order the wrong one and the cable is too short – that’s a redo job you don’t get paid for.

Cooling System: What the Manual Actually Shows

Group 7 – Cooling. The manual breaks radiators by engine: 2.4L [EDZ] in Fig. 7-110, 3.3L/3.8L [EGA, EGH, EGM] in Fig. 7-120. Same for water pumps, pulleys, drive belts. The belt section lists part numbers for the 2.4L single belt and the 3.3L/3.8L belt – lengths are different. If you throw a generic belt on a 3.8L, you might get belt slip or a thrown belt. Fig. 7-610 covers the transaxle oil cooler lines, which are different on AWD models. This manual saves you from that mistake.

I’ve been wrenching for 28 years. I have seen the aftermath of aftermarket “universal” manuals that skip the VIN-to-part cross-reference. This is a factory DaimlerChrysler document. You can compare it to the Automotive Industry Overview standards, but the point is: OEM data is the only reliable source for parts procurement.

Who Needs This 634-Page Document?

DIYers who own a 2007 RS-platform minivan. Shop owners who work on Caravan, Grand Caravan, Town & Country, Voyager, and Grand Voyager. If you are trying to figure out which navigation kit fits an RB4 versus RB1 radio (Fig. 1-130 vs Fig. 1-135), or which roof carrier kit works with the factory crossbars (Fig. 1-250 Luggage Roof), this manual has the exact part number and installation figure. The index returns to model year 2007RS and vehicle family 2007. So if you’re restoring a 2005 Voyager, the VIN decoding still applies, but the specific part illustrations may differ – you need the model-year-specific manual. DaimlerChrysler Caravan Voyager 2005 VIN Decoding Info covers earlier years.

Source Validity: OEM DaimlerChrysler, Not a Reprint

This is the original file: DaimlerChrysler_Caravan-Grand_Caravan-Town_Country-Voyager_Technical_Manual_Section_Exterior_Appearance_en-20013001321.pdf. It came from DaimlerChrysler’s internal parts system. Compare this to a third-party “compilation” that mixes in generic images and wrong torque values – that’s what causes bolts to snap. I’ve had to helicoil bellhousing holes because a guy used a manual that listed 45 ft-lbs instead of 55 ft-lbs for the torque converter bolts. This manual doesn’t have that problem because it’s factory specification.

If you are looking for an actual service manual with step-by-step engine removal, this is a parts manual – not a repair guide. But it pairs perfectly with the service manual for ordering. Daimlerchrysler Commercial Vehicle 2004 Technical Manual – Factory Brake Design and DaimlerChrysler Crossfire Technical Manual – 3307 Pages of Factory Specs are other factory documents for different platforms. Automotive Industry Overview gives context on why OEM documentation matters.

FAQ

Does this manual include torque specs?

No. This is a parts catalog, not a service manual. Torque values for fasteners are not listed.

What engines does it cover for the Grand Voyager?

The manual covers 2.4L [EDZ], 3.3L [EGA], and 3.8L [EGH, EGM] engines. The cooling group (Group 7) shows separate figures for each engine family. The VIN decoding table in position 8 tells you the engine code, so you can identify which engine your Grand Voyager has. For example, position 8 code “1” is the 2.4L, “2” is the 3.3L, “3” is the 3.8L. You need that to order the correct water pump, radiator, or drive belt. The manual also includes transaxle oil cooler lines for each engine variant – different hose routing for short wheelbase vs long wheelbase with or without CYC. If you have a 2007 Grand Voyager with the 3.8L and you need a cooling fan assembly, the part number is in Fig. 7-520 under “Drive Belts, 3.3L, 3.8L”. Yes, it’s grouped under belts, but the figure contains the fan assembly reference. That’s how factory parts manuals work – you cross-reference by figure.

Can I use this for a 2006 model?

Partially. The VIN decoding on page 1 applies to 2007 model year RS vehicles. Some parts, like Mopar accessories (Group 1), may fit 2006 models, but the front suspension (Group 2) and brake lines (Group 5) changed. Verify part numbers against a 2006-specific manual. DaimlerChrysler Caravan Voyager 2005 VIN Decoding Info covers 2005.

Is this a service manual or a parts manual?

It is a factory parts catalog – 634 pages of part numbers, figures, and VIN decoding. It tells you exactly which Mopar component to order, but it does not contain service procedures like how to remove the engine or change the transmission. For repair steps, you need the separate factory service manual (FSM). This manual complements the FSM so you order the right part the first time.

You want a manual that gives you the factory part number for a parking brake lever (Fig. 4-110) or the correct fog light kit (Fig. 1-610) without guessing. This is that manual. 634 pages, direct from DaimlerChrysler. Access the Factory Manual now and keep it on your shop tablet. Your guys will stop ordering the wrong water pump. Your customers will stop waiting. That’s worth the price of admission.