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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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Caravan

Year:

Codes

Platform:

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:

Searchable Text:

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:

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:

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:

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

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.