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Chrysler Grand Caravan 2005-2007 Service Repair Manual

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The Chrysler Grand Caravan, produced for the 2005, 2006, and 2007 model years under the RT chassis code, represents a significant evolution in the minivan segment, a category pioneered by...
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Chrysler Grand Caravan 2005-2007 Service Repair Manual
The Chrysler Grand Caravan, produced for the 2005, 2006, and 2007 model years under the RT chassis code, represents a significant evolution in the minivan segment, a category pioneered by Chrysler. These vehicles are known for their versatility, spacious interiors, and family-oriented features, making them a popular choice for transporting passengers and cargo. Engineered for reliability and practicality, the Grand Caravan offers a comfortable driving experience and a robust platform designed to meet the demands of daily use and long-distance travel. Its legacy is built on providing innovative solutions for family mobility, combining ample passenger seating with flexible cargo configurations. This comprehensive service and repair workshop manual provides detailed information essential for the maintenance and repair of your Chrysler Grand Caravan. It covers all major vehicle systems, including engine mechanical and electrical components, fuel and emission control systems, transmissions, suspension, steering, brakes, and body electrical and interior systems. Within its pages, you will find step-by-step repair procedures, diagnostic troubleshooting guides, wiring schematics, and technical specifications, all presented in clear, concise English with supporting illustrations. This manual is an invaluable resource for independent auto service professionals, DIY mechanics, and informed vehicle owners seeking to maintain their vehicle's performance and longevity.
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Grand Caravan
Years Covered:
2005, 2006, 2007
Generation
Generation Code:
RT
Codes
Chassis Code:
NS
👋 Introduction
Market Position
Target Audience:
Independent auto service professionals, DIY mechanics, informed vehicle owners
Value Proposition:
Saves money on repairs, empowers owners with knowledge, provides dealer-level repair information
Competitive Analysis
Differentiation:
Vehicle-specific, not generic; factory-level accuracy; covers all major systems
Key Features
Accuracy And Clarity:
Accurate, clear, concise text with supporting illustrations and diagrams
Completeness:
Covers all major topics with no missing or corrupt parts
📋 Manual Details
Coverage Areas
Covered Years:
2005-2007
Regions Covered:
North America (primary market for Grand Caravan)
Page Count
Estimated Page Count:
Over 2000 (typical for comprehensive service manuals of this era)
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full diagnostics, repair, and overhaul procedures for all engine variants
Engine Electrical:
Wiring schematics, component testing, diagnosis of ignition, starting, charging, and ECU systems
Emission Control:
Component identification, function, diagnosis, and repair of emissions-related systems
Fuel System:
Fuel injection, fuel pump, injectors, fuel lines, evaporative emission control (EVAP) system
Clutch System:
Procedures for manual transmission clutch inspection, replacement, and adjustment
Manual Transaxle:
Detailed repair, overhaul, and troubleshooting for manual transmissions
Automatic Transaxle:
Complete diagnostic, repair, and overhaul procedures for automatic transmissions
Driveshaft And Axle:
Inspection, repair, and replacement of driveshafts, CV joints, and axles
Suspension System:
Diagnosis and repair of struts, shocks, control arms, springs, bushings, and wheel bearings
Steering System:
Power steering, steering column, steering rack/gearbox, tie rods, and alignment procedures
Restraint System:
Airbag system diagnosis, components, and safety precautions; seat belt mechanisms
Brake System:
ABS, hydraulic system, brake pads, rotors, calipers, lines, bleeding procedures
Body Interior Exterior:
Panel removal/installation, trim, doors, windows, locks, seats, interior components
Body Electrical:
Lighting, power accessories, power windows/doors, interior/exterior lighting controls, body control module (BCM)
HVAC:
Heating, ventilation, air conditioning system diagnosis, repair, refrigerant handling, and components
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Troubleshooting:
Systematic diagnostic procedures for common and complex issues
Repair:
Step-by-step instructions for component removal, repair, and reinstallation
Diagnostics:
Diagnostic trouble codes (DTCs), sensor data interpretation, component testing
Wiring Schematics:
Detailed electrical diagrams for all vehicle systems
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIYers
Content Type:
Step-by-step instructions, diagrams, illustrations, specifications, troubleshooting guides
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text due to PDF format (dependent on original scan quality)
Print Quality
Printability:
Yes, individual pages or sections can be printed
Resolution:
High resolution for clear viewing and printing of diagrams and text
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
Compatibility
Operating Systems:
All Versions of Windows and Mac
Reader Requirement:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Options 2005:
3.3L V6 (EGA), 3.8L V6 (L32), 2.4L I4 (ED4 - less common on Grand Caravan)
Engine Options 2006:
3.3L V6 (EGA), 3.8L V6 (L32), 4.0L V6 (N/A - introduced later)
Engine Options 2007:
3.3L V6 (EGA), 3.8L V6 (L32), 4.0L V6 (N/A)
Performance
3.3L V6 Horsepower:
Approximately 180-185 hp
3.8L V6 Horsepower:
Approximately 200-205 hp
3.3L V6 Torque:
Approximately 200-205 lb-ft
3.8L V6 Torque:
Approximately 230-235 lb-ft
Fuel System
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Standard Transmission Type:
4-speed Automatic Transaxle (41TE/42LE variants common)
Optional
Optional Transmission Type:
5-speed Manual Transaxle (less common on Grand Caravan, more on Dodge Caravan/Plymouth Voyager)
Features
Transmission Control:
Electronic Control Unit (ECU) controlled automatic transmission
📐 Dimensions
Exterior
Body Style:
Minivan
Wheelbase Inches:
Approx. 119.2 inches
Length Inches:
Approx. 200.6 inches
Weights
Curb Weight Lbs:
Approx. 4300-4700 lbs (depending on configuration and engine)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
5 Stars (Driver and Passenger) for 2005-2007 models
NHTSA Side Impact Rating:
5 Stars (Front and Rear Occupants) for 2005-2007 models
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Traction Control (ASR), Electronic Stability Program (ESP - optional/standard on higher trims)
Passive Features
Passive Safety Features:
Multi-stage front airbags, front seat-mounted side airbags, available rear-seat airbags, front and rear crumple zones, side-impact door beams
💡 Technology Features
Infotainment
Infotainment Systems:
Optional DVD entertainment system, Sirius satellite radio, available Uconnect infotainment systems on later models.
Driver Assistance
Driver Assistance Features:
ParkView Rear Back-Up Camera (optional), ParkSense Rear Park Assist (optional).
Connectivity
Connectivity Options:
Optional Uconnect hands-free communication system with Bluetooth.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions (refer to manual for specifics)
Spark Plug Replacement:
Around 100,000 miles for most ignition systems (check manual for specific plug type and interval)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (most common, confirm in manual)
Transmission Fluid Type:
Chrysler ATF+4 (MS-9602)
Coolant Type:
HOAT (Hybrid Organic Acid Technology) Mopar OAT coolant
Known Issues
Common Issues Powertrain:
Transmission solenoid issues (especially on older models), occasional head gasket leaks on certain engine variants, intake manifold gasket leaks.
Common Issues Suspension Steering:
Worn control arm bushings, tie rod ends, and sway bar links are common wear items due to vehicle weight and family hauling.
Common Issues Electrical:
Power window regulators, faulty door lock actuators, HVAC blower motor resistor failure, CAN bus communication issues.
Common Issues Body:
Power sliding door mechanisms can be problematic, rear liftgate struts, minor body rust on common areas.
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler pioneered the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984, and the Grand Caravan has been a staple since.
Model Evolution
Generation Rt Introduction:
The 2005 model year marked the introduction of the fourth generation (RT body style) Chrysler minivans, featuring significant redesigns.
Production
Production Location:
Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Popular Mechanics Editor Choice:
Chrysler minivans (including Grand Caravan) have historically received accolades from automotive publications for practicality and innovation.
Consumer Ratings:
Generally well-regarded for interior space, versatility, and family-friendliness, though specific ratings vary by year and feature set.
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