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Chrysler Caravan 2005 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Year: 2005 Codes Platform: NS Generation: Fourth Generation (2001-2007) 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, fleet operators, DIY...
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Chrysler Caravan 2005 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler
Model:
Caravan
Year:
2005
Codes
Platform:
NS
Generation:
Fourth Generation (2001-2007)
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Audience:
Families, fleet operators, DIY mechanics
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Mercury Monterey
Key Features
Vehicle Highlights:
Spacious interior, flexible seating (Stow 'n Go optional on some trims/later models, but not standard in 2005), comfortable ride, multiple powertrain options.
Manual Value Proposition:
Provides in-depth technical information for accurate diagnosis and repair, enabling cost savings for owners and efficient service for professionals.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Language:
English
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
3.3L V6 (EGA), 3.8L V6 (L32)
Transmission:
4-Speed Automatic (41TE, 42LE)
Brakes:
Front Disc, Rear Drum (ABS optional)
Suspension:
Front Independent MacPherson Struts, Rear Solid Axle with Track Bar
Steering:
Power Rack and Pinion
Electrical:
Complete system diagnostics, wiring diagrams, modules, sensors, lighting, power accessories
Body:
Interior trim, exterior panels, doors, glass, climate control system, power sliding doors
HVAC:
Air Conditioning, Heating, Ventilation, Recirculation, Dual Zone Controls
Safety Systems:
Airbags, Seatbelts, ABS (Anti-lock Braking System)
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection
Repair:
Engine component replacement (e.g., head gaskets, water pump), transmission rebuild, brake system repair, suspension component replacement, electrical diagnostics and component replacement
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation
Disassembly Assembly:
Step-by-step guides for component removal and reinstallation
Specifications:
Torque specifications for fasteners, clearances, fluid capacities, electrical component resistance values
Technical Depth
Depth:
Comprehensive; covers basic maintenance to advanced diagnostics and major component overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Print Quality
Resolution:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EGA
Engine Displacement 1:
3.3 Liters (3301 cc)
Engine Type 1:
3.3L OHV V6
Horsepower 1:
180 hp @ 5000 rpm
Torque 1:
200 lb-ft @ 3200 rpm
Optional Engine
Engine Code 2:
L32
Engine Displacement 2:
3.8 Liters (3778 cc)
Engine Type 2:
3.8L OHV V6
Horsepower 2:
205 hp @ 5000 rpm
Torque 2:
230 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Cooling System
Coolant Type:
HOAT (Hybrid Organic Acid Technology) - Mopar Antifreeze/Coolant (MS-9769 or equivalent)
🔧 Transmission
Standard
Type 1:
4-Speed Automatic Transaxle
Model Designation 1:
41TE
Optional
Type 2:
4-Speed Automatic Transaxle
Model Designation 2:
42LE (Heavy Duty)
Features
Transmission Fluid:
ATF+4 (Chrysler Material Standard MS-9602)
Fluid Capacity:
Approximately 10.4 quarts (9.8 liters) for 41TE/42LE (dry fill)
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
196.5 inches (5000 mm)
Width:
78.5 inches (1994 mm)
Height:
68.4 inches (1737 mm)
Interior
Passenger Volume:
Approx. 140-160 cubic feet (depending on configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20-30 cubic feet
Cargo Volume With 3Rd Row Folded:
Approx. 70-80 cubic feet
Cargo Volume With 2Nd And 3Rd Row Folded:
Approx. 140-160 cubic feet
Weights
Curb Weight:
Approx. 4,200 - 4,600 lbs (1905 - 2087 kg)
Gross Vehicle Weight Rating:
Approx. 5,800 - 6,150 lbs (2631 - 2790 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars (2005 Model Year)
NHTSA Frontal Impact Passenger:
4 Stars (2005 Model Year)
NHTSA Side Impact Front Seat:
5 Stars (2005 Model Year)
NHTSA Side Impact Rear Seat:
5 Stars (2005 Model Year)
Active Features
ABS:
Optional Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some models
Passive Features
Airbags Front:
Standard Multi-Stage Driver and Front Passenger Airbags
Airbags Side:
Optional Supplemental Side Curtain Airbags (front and second row)
Seatbelts:
Three-point seat belts in all seating positions, front seatbelt pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional premium audio systems (e.g., Infinity).
Rear Seat Entertainment:
Optional rear-seat entertainment system with DVD player available on some trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional rear parking assist sensors on some models.
Connectivity
Auxiliary Input:
Not commonly available from factory in 2005 models; aftermarket solutions exist.
Usb Ports:
Not available from factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 3 months (traditional) or up to 6,000 miles/6 months with synthetic oil and filter. Refer to Owner's Manual for specific recommendations.
Engine Coolant Flush:
Every 30,000 miles or 2 years for HOAT coolant.
Transmission Fluid Change:
Every 30,000 - 60,000 miles, depending on driving conditions. ATF+4 is a 'fill for life' fluid under normal conditions, but regular checks and changes are recommended for longevity.
Spark Plug Replacement:
3.3L: 100,000 miles (original platinum plugs); 3.8L: 100,000 miles (original platinum plugs). Consult manual for specific plug type.
Fluid Specifications
Engine Oil Type 3.3L:
SAE 5W-30 (API Certified)
Engine Oil Type 3.8L:
SAE 5W-30 (API Certified)
Engine Oil Capacity 3.3L:
4.7 quarts (4.4 liters) with filter change
Engine Oil Capacity 3.8L:
5.0 quarts (4.7 liters) with filter change
Power Steering Fluid:
ATF+4 (Chrysler Material Standard MS-9602)
Brake Fluid:
DOT 3
Known Issues
Transmission Slipping:
Common in higher mileage vehicles, often related to wear on the torque converter clutch or transmission fluid degradation. The 41TE/42LE transmissions can be sensitive to fluid condition.
Headliner Sagging:
The adhesive holding the fabric to the backing board can fail over time, causing the headliner to sag.
Power Door Lock Actuator Failure:
Actuators for sliding doors or regular doors can fail, leading to non-functioning locks.
Idler Pulley Noise:
The idler pulley for the accessory drive belt can become noisy and require replacement.
Blend Door Actuator Failure:
HVAC system blend door actuators can fail, leading to improper temperature control or airflow direction.
📚 Vehicle History
Brand Heritage
Chrysler Legacy:
Chrysler has a long history of innovation in the minivan segment, introducing the original minivan concept in the early 1980s.
Model Evolution
Caravan Lineage:
The Caravan, alongside its Dodge Grand Caravan sibling, is a cornerstone of Chrysler's minivan offerings, continuously evolving in design, technology, and functionality.
Production
Manufacturing Locations:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Generation Years:
2001-2007 (Fourth Generation)
🏆 Awards & Recognition
Recognitions
Car Of The Year:
Chrysler minivans have historically received numerous awards and accolades, though specific 2005 Caravan awards are less prominent than its foundational achievements.
Ratings
IIHS Ratings:
Generally good frontal and side impact ratings from IIHS for this generation, but specific ratings vary by exact configuration and year.
Certifications
Emisiones Standards:
Meets EPA emissions standards for 2005 model year vehicles.
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