🏷️ Basic Information

Make:

Chrysler, Dodge, Voyager

Model:

Town & Country, Caravan, Grand Caravan, Grand Caravan C/V, Voyager, Grand Voyager

Year:

2005

Platform Code:

RG

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance personnel

Value Proposition:

Provides detailed, actionable information for servicing a wide range of models and powertrains within the RG platform, aiming to save owners significant repair costs compared to dealership service.

Features:

Instant download, printable pages, comprehensive coverage of multiple model variants and engine options, high-quality diagrams.

📋 Manual Details

Vehicles Covered:

Chrysler Caravan (FWD), Chrysler Town & Country (FWD), Dodge Caravan/Grand Caravan (FWD), Dodge Caravan C/V, Grand Caravan C/V (FWD), Chrysler Town & Country (AWD), Dodge Grand Caravan (AWD), Chrysler Voyager/Grand Voyager (FWD, LHD), Chrysler Voyager/Grand Voyager (AWD, LHD), Chrysler Voyager/Grand Voyager (FWD, RHD), Chrysler Voyager/Grand Voyager (AWD, LHD)

Regions:

North America (implied by model names), Global (for RHD/LHD Voyager variations)

Estimated Pages:

High Volume (typical for comprehensive workshop manuals of this era, likely 1500+ pages when compiled from original sources)

Type:

Workshop Service Repair Manual

Language:

English

File Format:

PDF

Compatibility:

All Versions of Windows & Mac

Reader Requirement:

Adobe PDF Reader

📖 Manual Coverage

Powertrain:

Engine Systems, Fuel System, Exhaust System, Cooling System, Automatic Transmission, Clutch (for manual transmission variations if applicable, though less common on this platform), Driveline, Differential

Chassis:

Suspension (Front and Rear), Steering, Brakes (Front and Rear, ABS), Tires/Wheels, Frame & Bumpers

Body & Interior:

Body (Exterior and Interior Components), Doors, Windows, Seats, Audio System, Instrument Cluster, Lamps, Wipers/Washers, Heating & Air Conditioning (HVAC), Restraints (Airbags, Seatbelts)

Electrical & Electronics:

Electronic Control Modules (ECMs/PCMs), Ignition Control, Power Systems (Battery, Charging, Starting), Vehicle Theft Security, Speed Control, Horn, Chime/Buzzer, Message Systems, Wiring Diagrams

General Maintenance:

Lubrication, Fluid Checks and Changes, Filter Replacements, Belt Inspections and Replacements, Spark Plug Service, Tire Rotation and Pressure Checks

Troubleshooting:

Diagnostic Procedures, Symptom-Based Troubleshooting Guides, Fault Code Interpretation (OBD-II)

Repair And Rebuild:

Engine Repair (major and minor), Transmission Overhaul, Brake Component Replacement, Suspension Component Replacement, Steering System Repair, HVAC Component Servicing, Electrical Component Diagnosis and Replacement

Installation:

Component Replacement and Installation for most systems

Depth:

Comprehensive: Covers basic maintenance to in-depth diagnostics and major component overhauls, including detailed torque specifications, clearance measurements, and electrical schematics.

📊 Manual Specifications

Print Quality:

High Quality (implied by 'high quality diagrams' and printable pages)

Searchability:

Likely searchable text within PDF (standard for professionally compiled manuals)

Binding Type:

Digital Download (Printable pages)

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

2.4L I4:

Engine Code: Likely G4BA (MPI, DOHC, 16-Valve). Displacement: 2378 cc. Bore x Stroke: 87.5 x 96 mm. Horsepower: Approx. 150 hp @ 5800 rpm. Torque: Approx. 160 lb-ft @ 4000 rpm. Fuel System: Multi-Point Fuel Injection (MPI). Configuration: Inline 4-Cylinder. Valvetrain: Dual Overhead Camshaft (DOHC).

3.3L V6:

Engine Code: EGA (OHV, SMPI, Flex Fuel). Displacement: 3301 cc. Bore x Stroke: 93 x 81 mm. Horsepower: Approx. 180-185 hp @ 5000-5200 rpm. Torque: Approx. 205-210 lb-ft @ 3600-4000 rpm. Fuel System: Sequential Multi-Point Fuel Injection (SMPI). Configuration: V-Configuration (6-Cylinder). Valvetrain: Overhead Valve (OHV). Fuel Type: Gasoline/Ethanol (Flex Fuel capability).

3.8L V6:

Engine Code: Egi (OHV, SMPI). Displacement: 3778 cc. Bore x Stroke: 96 x 87.5 mm. Horsepower: Approx. 200-205 hp @ 5000-5200 rpm. Torque: Approx. 230-240 lb-ft @ 4000-4400 rpm. Fuel System: Sequential Multi-Point Fuel Injection (SMPI). Configuration: V-Configuration (6-Cylinder). Valvetrain: Overhead Valve (OHV).

2.8L I4 Turbo Diesel:

Engine Code: Likely VM Motori R428 (Common Rail Turbo Diesel). Displacement: 2766 cc. Configuration: Inline 4-Cylinder. Valvetrain: DOHC. Fuel System: Turbocharged Direct Injection (Common Rail). Horsepower/Torque figures vary by specific tune and market, typically around 150-170 hp and 250-270 lb-ft torque.

2.5L I4 Turbo Diesel:

Engine Code: Likely VM Motori R425 (Turbo Diesel). Displacement: 2499 cc. Configuration: Inline 4-Cylinder. Valvetrain: SOHC or DOHC. Fuel System: Turbocharged Direct Injection. Horsepower/Torque figures vary by specific tune and market, typically around 115-130 hp and 200-230 lb-ft torque.

Acceleration 0 60:

Varies significantly by engine and drivetrain configuration, typically 9-12 seconds for V6 models.

Fuel Type:

Unleaded gasoline (MPI, SMPI), E85 (Flex Fuel variants), Diesel (Turbo Diesel variants)

Fuel Tank Capacity:

Typically around 18-20 gallons (68-76 liters), varies by model and configuration.

🔧 Transmission

Automatic Transmission:

Chrysler's 4-speed automatic transmission (e.g., 41TE/42LE variants) was common on V6 engines. Some later models or specific configurations might have had 6-speed automatics, but for 2005, 4-speed is highly probable for the majority.

All Wheel Drive System:

Available on certain models (e.g., Grand Caravan AWD, Town & Country AWD). This system typically utilizes a transfer case and a rear differential to distribute power.

Transmission Fluid Type:

Typically ATF+4 (Mopar part number 05013457AA or equivalent)

📐 Dimensions

Wheelbase:

Standard wheelbase approximately 112.5 inches (2858 mm). Long wheelbase (Grand Caravan/Grand Voyager) approximately 119.2 inches (3028 mm).

Length:

Varies by model and wheelbase, e.g., standard 189.8 inches (4821 mm), long 196.9 inches (5001 mm).

Curb Weight:

Ranges from approximately 3,700 lbs (1678 kg) for FWD 4-cyl models to over 4,500 lbs (2041 kg) for AWD V6 models.

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (for 2005 models based on typical performance of this generation)

NHTSA Front Impact Passenger:

4 Stars (for 2005 models based on typical performance of this generation)

IIHS Moderate Overlap Front:

Good (for models equipped with side airbags, Good for earlier models without)

ABS:

Standard Anti-lock Braking System

Traction Control:

Optional or standard depending on trim level and drivetrain

Airbags:

Standard front airbags; optional side-impact airbags for front occupants and available side-curtain airbags for all rows.

💡 Technology Features

Audio System:

Standard AM/FM/CD player, with optional premium Infinity sound systems, rear seat entertainment systems (DVD players), and satellite radio capability.

Cruise Control:

Standard speed control (cruise control) system.

Auxiliary Input:

Not typically standard for this model year, but aftermarket options exist.

🔧 Maintenance

Oil Change Interval:

Typically 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first, depending on driving conditions and oil type used (synthetic recommended for longer intervals).

Transmission Fluid Change Interval:

Recommended every 30,000 - 60,000 miles (48,000 - 96,000 km), or sooner under severe service conditions. ATF+4 is generally considered a 'fill for life' fluid by some, but regular checks and changes are advisable for longevity.

Coolant Change Interval:

Initial change at 100,000 miles (160,000 km), then every 50,000 - 60,000 miles (80,000 - 96,000 km). Use Mopar OAT (Organic Additive Technology) coolant or equivalent.

Engine Oil Specification:

API Certified SAE 5W-20 or 5W-30 (check owner's manual for specific viscosity for each engine). Chrysler MS-6395 standard recommended.

Power Steering Fluid:

ATF+4 or Chrysler MS-5901

Brake Fluid:

DOT 3 or DOT 4

Transmission Issues:

Early generation 4-speed automatics could be prone to torque converter shudder, solenoid failures, or internal wear. Regular fluid changes are critical. Power transfer unit (PTU) seals on AWD models can leak.

Engine Issues:

The 3.3L and 3.8L V6 engines are generally robust, but can experience intake manifold gasket leaks, oil leaks (valve cover gaskets), and occasional radiator or cooling fan issues. The 2.4L I4 can have piston ring wear. Diesel engines require specific care regarding fuel system cleanliness and glow plug operation.

Suspension Steering:

Wear in ball joints, tie rod ends, and control arm bushings is common due to the vehicle's weight and usage. Power steering pumps can sometimes fail. Rear suspension spring sag can occur.

Electrical Issues:

Instrument cluster failures (dead pixels, flickering gauges), HVAC blower motor resistor failure, and intermittent power issues related to body control modules (BCM) or ignition switches can occur.

Body Related Issues:

Power sliding door mechanisms can fail, rear liftgate struts can weaken, and rust can form on lower body panels, wheel wells, and rocker panels, particularly in areas with road salt.

📚 Vehicle History

Chrysler Dodge Heritage:

Chrysler Corporation (later DaimlerChrysler) has a long history of producing minivans, pioneering the segment with the original Dodge Caravan and Plymouth Voyager in the mid-1980s. The 'Town & Country' nameplate has also been used for luxury variants.

Rg Platform Generation:

The RG platform represented the fourth generation of Chrysler's minivans, introduced for the 2001 model year. This generation saw significant updates in styling, interior packaging, and powertrain options. The 2005 model year often includes mid-cycle refresh updates.

Manufacturing Locations:

Primarily manufactured in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

🏆 Awards & Recognition

Car And Driver Five Best:

The Chrysler minivans often received accolades and awards from automotive publications during their production years, including multiple 'Five Best' lists from Car and Driver for their segment-defining capabilities and versatility.