🏷️ Basic Information

Make:

Dodge

Model:

Grand Caravan

Model Years Covered:

2005, 2006, 2007

Product Type:

Workshop Service Manual

Product Name:

Dodge Grand Caravan 2005 2006 2007 Repair Service Manual PDF

👋 Introduction

Vehicle Segment:

Minivan

Target Demographic:

Families, fleet operators

Key Competitors:

Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Uplander.

Vehicle Type:

Front-engine, front-wheel-drive minivan.

Versatility:

Known for its flexible seating arrangements (Stow 'n Go introduced in later models), ample cargo space, and family-friendly features.

Value Proposition:

Offered a strong balance of features, space, and affordability in its segment.

📋 Manual Details

Primary Audience:

Mechanical Technicians

Estimated Page Count:

1500+

Manual Type:

Comprehensive Workshop Repair Manual

Language:

English

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, cylinder head, block assembly, pistons, rings, crankshaft, camshafts, valve train, timing system (belts/chains), lubrication system, cooling system.

Engine Performance:

Fuel system (injectors, pump, pressure regulator), ignition system (coils, plugs, sensors), emissions control systems (EGR, catalytic converter), engine control module (ECM) diagnostics.

Transmission Automatic:

Automatic transaxle overhaul, torque converter, valve body, solenoids, seals, clutches, bands, lubrication, electronic control.

Transmission Manual:

N/A (This generation primarily featured automatic transmissions)

Brakes:

Front and rear brake systems, hydraulic components (master cylinder, lines, calipers, wheel cylinders), disc and drum brake service, parking brake system, Anti-lock Braking System (ABS) diagnosis and component replacement.

Suspension:

Front and rear suspension components (struts, shocks, springs, control arms, ball joints, bushings), steering linkage, alignment specifications.

Steering:

Power steering system (pump, rack and pinion, hoses, fluid), steering column, ignition lock cylinder.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition switch, lighting systems (headlamps, taillamps, interior), fuses, relays, wiring diagrams.

Body And Chassis:

Body panel removal and installation, interior trim, door mechanisms, liftgate, power sliding doors, glass replacement, chassis components, rust repair.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, components (compressor, condenser, evaporator, blower motor), refrigerant service, climate control unit.

Infotainment And Electronics:

Radio, audio systems, navigation system (if equipped), power accessories (windows, locks, mirrors), instrument cluster.

Routine Maintenance:

Oil and filter change, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-offs.

Troubleshooting:

Systematic diagnostic procedures for all major vehicle systems, common fault symptom diagnosis, diagnostic trouble codes (DTCs) interpretation.

Repair Procedures:

Step-by-step repair instructions for all components, including torque specifications, special tool requirements, and assembly/disassembly sequences.

Component Replacement:

Detailed instructions for replacing major components such as engines, transmissions, alternators, starters, brake calipers, suspension parts, and body panels.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, aiding in diagnosis and repair of electrical faults.

Diagnostic Capabilities:

Advanced diagnostic procedures, including specific tests for sensors, actuators, and control modules. Interpretation of OBD-II diagnostic trouble codes.

Rebuild Instructions:

Detailed specifications and procedures for engine and transmission rebuilds, including tolerances, clearances, and assembly sequences.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair and diagnostic procedures.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable text content for quick information retrieval.

Print Quality:

High-resolution digital format, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code Base:

EHB

Engine Displacement Base:

3.3 Liters (3301 cc)

Engine Type Base:

3.3L SOHC V6

Horsepower Base:

180 hp @ 5000 rpm

Torque Base:

205 lb-ft @ 3400 rpm

Engine Code Optional:

EGA

Engine Displacement Optional:

3.8 Liters (3778 cc)

Engine Type Optional:

3.8L SOHC V6

Horsepower Optional:

205 hp @ 5000 rpm (approx.)

Torque Optional:

240 lb-ft @ 3000 rpm (approx.)

Fuel Delivery:

Electronic Multi-Port Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Transmission Type Standard:

4-speed Automatic Transaxle

Transmission Type Optional:

N/A (4-speed automatic was standard across all engines for these years)

Transmission Control:

Electronically controlled with overdrive.

Fluid Type:

ATF+4 (MS-9602)

📐 Dimensions

Wheelbase:

Approx. 119.2 inches

Overall Length:

Approx. 199.5 inches

Overall Width:

Approx. 74.0 inches

Overall Height:

Approx. 68.9 inches

Cargo Volume Behind 3Rd Row:

Approx. 30.3 cu. ft.

Cargo Volume Behind 2Nd Row:

Approx. 80.3 cu. ft. (with 2nd row folded/removed)

Cargo Volume Maximum:

Approx. 143.8 cu. ft. (with 2nd and 3rd rows folded/removed)

Curb Weight Base:

Approx. 4300 - 4500 lbs (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Approx. 5800 - 6000 lbs

Towing Capacity:

Up to 3800 lbs (with optional towing package)

🛡️ Safety Features

NHTSA Front Crash Test Rating:

Good (driver and passenger in frontal impact)

NHTSA Side Impact Crash Test Rating:

Good (front and rear passenger in side impact)

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Airbags Standard:

Frontal airbags for driver and front passenger.

Airbags Optional:

Available front-side airbags and rear-seat side airbags (depending on trim).

Seatbelts:

3-point seat belts in all seating positions; pretensioners for front seats.

Child Safety Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Audio System:

Factory AM/FM/CD player; optional Infinity speaker systems, rear-seat entertainment (DVD player and screens).

Navigation:

Optional factory navigation system (typically integrated into the head unit).

Parking Sensors:

Optional rear parking assist sensors.

Power Outlets:

12V power outlets for accessory charging.

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 5,000 miles or 3-6 months, depending on driving conditions and oil type used. Consult manual for severe duty recommendations.

Air Filter Replacement:

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

Spark Plug Replacement:

30,000 - 60,000 miles (depending on plug type, e.g., platinum or iridium).

Transmission Fluid Change:

Every 30,000 - 50,000 miles or as specified in the owner's manual, especially under towing conditions.

Coolant Flush:

Every 30,000 - 50,000 miles or 2-3 years.

Engine Oil Specification:

SAE 5W-20 or SAE 10W-30 (refer to owner's manual for exact recommendation based on climate).

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) with filter for 3.3L; Approx. 5.0 quarts (4.7 liters) for 3.8L.

Coolant Type:

Chrysler HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant (Orange).

Brake Fluid Type:

DOT 3

Power Sliding Doors:

Malfunctioning or slow power sliding doors and liftgate mechanisms due to worn motors, cables, or sensors.

Transmission Issues:

Occasional transmission shifting problems or failure, particularly the 4-speed automatic, often related to internal wear or valve body issues.

Suspension Components:

Wear in front suspension components like ball joints, control arm bushings, and tie rod ends, leading to noise and steering issues.

Engine Mounts:

Degradation and failure of engine and transmission mounts, causing vibration and harshness, especially at idle.

Climate Control Actuators:

Failure of blend door actuators within the HVAC system, leading to improper temperature control or airflow direction.

📚 Vehicle History

Dodge Brand Context:

Dodge, a division of Chrysler (now Stellantis), has a long history of producing robust and often performance-oriented vehicles, including a strong presence in the minivan market.

Generation:

This generation (RS) represents the fourth generation of the Dodge Caravan/Grand Caravan line, introduced for the 2001 model year and facelifted for 2005.

2005 Facelift:

The 2005 model year brought significant updates including revised styling, improved interior materials, and the introduction of the highly popular Stow 'n Go seating system on many trims.

Model Run Years:

1984-2020 (Caravan/Grand Caravan lineage)

Manufacturing Plant:

Windsor Assembly Plant, Windsor, Ontario, Canada.

🏆 Awards & Recognition

Ward Auto Top 10 Engines:

The 3.8L V6 engine variant was recognized by Ward's AutoWorld for its power and refinement in its class during this era.

Insurance Institute Highway Safety IIHS Ratings:

Achieved 'Good' ratings in frontal and side impact crash tests from IIHS for these model years, reflecting strong safety performance.