Target Audience:
Family vehicles, flexible cargo/passenger transport
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Venture/Uplander
Versatility:
Spacious interior, Stow 'n Go seating (introduced later in this generation, may be present on later 2005-2007 models), flexible cargo capacity
Powertrain Options:
Reliable V6 engines offering a balance of power and efficiency for the segment
Engine Coverage:
3.3L V6 (EGA), 3.8L V6 (L32), 2.4L 4-Cylinder (ED1 - likely limited to earlier models or specific markets, but good to mention if present)
Transmission Coverage:
4-speed Automatic (40TE/41TE)
Body Styles:
Standard Wheelbase, Extended Wheelbase (Grand Caravan)
Estimated Page Count:
1500+
Manual Type:
Workshop Service Repair Manual
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, emissions control
Transmission Drivetrain:
Automatic transmission service, driveline components (axles, driveshafts)
Chassis:
Suspension (front and rear), steering system, brake system (front discs, rear drums/discs), wheels and tires
Electrical System:
Battery, charging system, starting system, lighting, instrument cluster, power accessories, body control module (BCM), engine control module (ECM), anti-lock braking system (ABS) module, airbag system module
Body Interior:
Body panels, doors, windows, interior trim, HVAC system, seating systems, power sliding doors (if equipped), power liftgate (if equipped)
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting, diagnostic trouble codes (DTCs) interpretation and resolution
Repair Overhaul:
Engine overhaul, transmission rebuild, brake component replacement, suspension component replacement, electrical component diagnosis and replacement, body panel repair
Special Procedures:
Timing belt inspection/replacement (if applicable to specific engine variant, though most Caravan engines of this era used chains), cylinder head removal and installation, fuel injector testing and replacement, ABS bleeding procedures, airbag system servicing precautions
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures.
Engine 3.3L V6:
3.3L (3301cc) OHV V6 (EGA engine code)
Engine 3.3L V6 Horsepower:
Approx. 180 hp @ 5000 rpm
Engine 3.3L V6 Torque:
Approx. 205 lb-ft @ 3400 rpm
Engine 3.8L V6:
3.8L (3778cc) OHV V6 (L32 engine code)
Engine 3.8L V6 Horsepower:
Approx. 200 hp @ 5000 rpm
Engine 3.8L V6 Torque:
Approx. 230 lb-ft @ 3200 rpm
Acceleration 0 60:
Approx. 8.5-10.0 seconds (depending on engine and configuration)
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded gasoline
Wheelbase Standard:
119.2 inches
Wheelbase Extended:
135.0 inches (Grand Caravan)
Overall Length Standard:
189.8 inches
Overall Length Extended:
205.6 inches (Grand Caravan)
Seating Capacity:
7 passengers (typical)
Cargo Volume Behind 3Rd Row Standard:
Approx. 100 cubic feet
Cargo Volume Behind 3Rd Row Extended:
Approx. 140 cubic feet (Grand Caravan)
Curb Weight Approx:
4000-4500 lbs (depending on configuration)
Towing Capacity Max:
Up to 3,800 lbs (with optional towing package)
NHTSA Frontal Driver:
Good (2005-2007 models)
NHTSA Frontal Passenger:
Good (2005-2007 models)
NHTSA Side Driver:
Acceptable (2005-2007 models - some configurations may vary)
NHTSA Side Passenger:
Acceptable (2005-2007 models - some configurations may vary)
IIHS Front Small Overlap:
N/A (Test not performed on these model years)
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS)
Airbags:
Frontal airbags for driver and front passenger, optional side-impact airbags
Seatbelts:
3-point seat belts for all seating positions, pretensioners for front seats
Audio System:
AM/FM stereo with CD player, optional cassette player, optional premium audio systems (e.g., Infinity).
Navigation:
Rarely available for this model year, typically aftermarket units.
Cruise Control:
Standard on most trims.
Auxiliary Input:
Not typically standard; aftermarket solutions or CD changers were common.
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (refer to manual for specific severe/normal duty recommendations and oil type).
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on driving conditions (check manual for specific guidance).
Spark Plug Replacement V6:
Approx. 100,000 miles (Long-life platinum or iridium plugs)
Engine Oil Spec:
SAE 5W-30 (API certified)
Coolant Spec:
Chrysler OAT (Organic Additive Technology) Antifreeze/Coolant (Mopar Part # 05010885AA or equivalent HOAT)
Transmission Slipping:
Common issue with the 41TE transmission, often related to torque converter clutch (TCC) solenoid failure or worn clutch packs. Fluid and filter changes are critical.
Engine Mounts:
Front and rear engine mounts can degrade over time, leading to vibrations and harshness, especially during acceleration/deceleration.
Power Sliding Door Motors:
Motors and mechanisms for power sliding doors can fail, leading to inoperable doors. Lubrication and adjustment are key.
Heater Core Leaks:
Heater core can develop leaks, often identified by a sweet smell or fogging windows. Access is often labor-intensive.
Ignition Coil Failures:
Individual ignition coils can fail, causing misfires and rough running. Typically requires replacement of the affected coil.
Parent Company:
Chrysler Corporation (later DaimlerChrysler)
Generation:
Fourth Generation (2001-2007)
Platform:
Chrysler RS platform, shared with Plymouth Voyager and Chrysler Town & Country.
Facelift:
Received a minor refresh for 2005 including updated front and rear styling, interior refinements, and available features.
Manufacturing Plant:
Windsor Assembly Plant, Windsor, Ontario, Canada; St. Louis Assembly Plant, Fenton, Missouri, USA (closed in 2004, production shifted)
