🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2005

Platform:

RS

Chassis Code:

NS (for earlier generations, RS for 2001-2007)

👋 Introduction

Market Position:

The Dodge Caravan (2005) was a highly popular minivan in its segment, known for its practicality, versatility, and family-oriented features. It competed directly with vehicles like the Honda Odyssey, Toyota Sienna, and Ford Freestar. This manual targets owners and technicians who need detailed information to maintain and repair this widely used vehicle.

Competitive Analysis:

The 2005 Caravan offered a strong value proposition within the minivan market. While its competitors might have offered more refined driving dynamics or advanced luxury features, the Caravan excelled in interior space, cargo flexibility, and available powertrain options, making it a favorite for large families and commercial use.

Key Features:

The 2005 model year continued to refine the successful fourth-generation platform, offering various seating configurations (like the Stow 'n Go system in later iterations of this generation, though potentially not standard on all 2005 models depending on trim), ample cargo space, and a comfortable ride. Powertrain options provided a balance of performance and efficiency for its class.

Target Audience:

Professional automotive technicians, dealership service departments, independent repair shops, and experienced DIY enthusiasts who need accurate and detailed repair information.

📋 Manual Details

Coverage Areas:

All systems, including engine, transmission, brakes, suspension, steering, electrical, HVAC, body, and accessories.

Page Count:

Estimated 2000+ pages (typical for a comprehensive workshop manual)

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (typically PDF)

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Control System (ECM), Fuel System, Ignition System, Cooling System, Exhaust System, Turbocharger (if applicable), Transmission (Automatic), Driveline, Suspension (Front and Rear), Steering System, Brake System (Hydraulic and Power), Anti-lock Brake System (ABS), Traction Control System (TCS), Electrical System (Wiring Diagrams, Components), Lighting System, Body Control Module (BCM), Powertrain Control Module (PCM), Climate Control (HVAC), Restraint Systems (Airbags, Seatbelts), Audio System, Power Accessories (Windows, Locks, Mirrors), Interior Trim, Exterior Body Panels, Glass, Bumpers.

Electrical System Detail:

Comprehensive wiring diagrams for all circuits, component location charts, connector pin-out data, troubleshooting flowcharts for electrical faults.

Fuel System Detail:

Fuel tank removal and installation, fuel pump testing and replacement, fuel injector diagnosis and cleaning, fuel pressure regulator testing, EVAP system diagnosis.

Procedures Included:

Scheduled maintenance, routine inspections, diagnostics, troubleshooting guides, repair procedures for all major components, component removal and installation, torque specifications, wiring diagram interpretation, special tool usage, diagnostic trouble codes (DTCs) and their resolutions, engine rebuild procedures, transmission overhaul, brake bleeding and service, suspension component replacement, steering system alignment, HVAC system servicing, electrical component testing and replacement, body panel repair, safety system checks.

Diagnostic Procedures:

Detailed step-by-step diagnostic procedures for all engine, transmission, ABS, airbag, and body control systems. Includes symptom-based diagnostics and OBD-II scan tool procedures.

Engine Repair Procedures:

Complete procedures for engine disassembly, assembly, cylinder head removal/installation, piston and connecting rod service, crankshaft and bearing inspection, camshaft timing, valve adjustments, and component replacement.

Technical Depth:

Comprehensive, suitable for professional technicians and advanced DIYers. Covers everything from basic fluid changes and filter replacements to in-depth engine and transmission diagnostics, complex electrical system troubleshooting, and bodywork repair.

Troubleshooting Methods:

Includes systematic troubleshooting for common drivability issues, electrical faults, HVAC problems, and body system malfunctions.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchability:

Searchable PDF text for quick access to specific topics, part numbers, and procedures.

Print Quality:

High-resolution scans optimized for digital viewing and printing. Includes clear diagrams, schematics, and illustrations.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Displacement:

3.3L (3301cc)

Engine Type:

Overhead Valve (OHV) V6

Engine Code:

EGA

Horsepower:

180 hp @ 5000 rpm (approximate)

Torque:

205 lb-ft @ 3200 rpm (approximate)

Engine Displacement:

3.8L (3778cc)

Engine Type:

Overhead Valve (OHV) V6

Engine Code:

L32

Horsepower:

200 hp @ 5000 rpm (approximate)

Torque:

240 lb-ft @ 3200 rpm (approximate)

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Emission Control:

Catalytic Converter, EGR (Exhaust Gas Recirculation), Oxygen Sensors

Engine Cooling System Type:

Pressurized, liquid-cooled, with electric cooling fan.

🔧 Transmission

Transmission Type:

4-Speed Automatic

Transmission Code:

41TE

Transmission Type:

N/A (4-speed automatic was standard across most trims for this year)

Transmission Fluid Type:

ATF+4 (Mopar)

Transmission Fluid Capacity:

Approx. 4.0 quarts (dry fill), 10.5 quarts (total capacity)

Transmission Cooling:

Integrated cooler in radiator, external cooler may be present on heavy-duty applications.

📐 Dimensions

Wheelbase:

119.3 inches

Overall Length:

191.5 inches

Overall Width:

73.0 inches

Overall Height:

67.5 inches

Front Track:

61.0 inches (approximate)

Rear Track:

61.4 inches (approximate)

Cargo Volume Behind 3Rd Row:

Approx. 30.4 cu ft

Cargo Volume With 3Rd Row Folded:

Approx. 77.1 cu ft

Cargo Volume With 2Nd And 3Rd Row Folded:

Approx. 143.1 cu ft

Curb Weight:

4,000 - 4,300 lbs (approximate, depending on engine and configuration)

Gross Vehicle Weight Rating Gvwr:

Approx. 5,775 lbs

🛡️ Safety Features

NHTSA Frontal Driver Rating 2005:

★★★★☆ (4 stars)

NHTSA Frontal Passenger Rating 2005:

★★★★☆ (4 stars)

IIHS Frontal Offset Rating 2005:

Acceptable

Active Features:

Anti-lock Braking System (ABS), Traction Control System (TCS - optional/standard depending on trim)

Passive Features:

Driver and front passenger airbags, front seat side airbags (optional), three-point seatbelts for all occupants, LATCH child seat anchors, available front seatbelt pretensioners.

Child Safety Features:

Rear door child safety locks, LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment System:

Factory installed AM/FM stereo with CD player, optional rear-seat entertainment system (RSE) with DVD player and screens, optional premium audio systems.

Driver Assistance Features:

Cruise control, optional rear parking assist sensors.

Connectivity Features:

Optional Sirius Satellite Radio, accessory power outlets.

Comfort Features:

Power windows, power door locks, power adjustable mirrors, automatic climate control (optional), remote keyless entry.

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 5,000 miles or 3-6 months (depending on driving conditions and oil type, consult manual for specifics).

Air Filter Replacement Interval:

Every 15,000 - 30,000 miles or as needed based on inspection.

Spark Plug Replacement Interval:

Approx. 100,000 miles (if using long-life plugs, e.g., platinum or iridium, check specific plug type).

Transmission Fluid Change Interval:

Every 30,000 - 60,000 miles or as specified for severe duty. Consult manual for precise interval.

Engine Oil Specification:

SAE 5W-30 (API certified, synthetic blend or full synthetic recommended for optimal performance and protection)

Coolant Specification:

Chrysler HOAT (Hybrid Organic Acid Technology) 50/50 mixture with distilled water. Color is typically orange/red.

Brake Fluid Specification:

DOT 3

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent (consult manual for specific type).

Known Issues:

Transmission solenoid failures (especially in the 41TE), potential for head gasket leaks on 3.3L/3.8L V6 engines, power door lock actuator failures, rust issues on wheel wells and rocker panels, HVAC blower motor resistor failures, intermittent electrical issues related to body control modules.

Common Repair Items:

Brake pad and rotor replacement, suspension component wear (ball joints, tie rods, struts), exhaust system repair, battery replacement, accessory belt replacement, fuel filter replacement.

📚 Vehicle History

Brand Heritage:

Dodge, as a division of Chrysler, has a long history in the automotive industry, known for its performance-oriented vehicles and, with the Caravan, its pioneering role in the minivan segment.

Model Evolution:

The Dodge Caravan, introduced in 1984 as part of the original K-car platform minivan revolution, has undergone several redesigns. The 2001-2007 models represent the fourth generation, which saw significant updates in styling, interior features, and powertrain options, including the introduction of the highly versatile Stow 'n Go seating.

Distinguishing Features Gen4:

The 4th generation saw a significant redesign from the 3rd generation, with a more aerodynamic profile and improved interior ergonomics. The 2005 model year represents a mid-cycle update or continuation of this generation's refinements.

Production Years Generation:

2001-2007 (Fourth Generation)

Manufacturing Location:

Windsor, Ontario, Canada (for North American market)