Chrysler Caravan 2005 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Year: 2005 Generation: Third Generation (RS) Codes Platform Code: NS/RS 👋 Introduction Market Position Vehicle Segment: Minivan Primary Competitors 2005: Honda Odyssey,...

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Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Caravan

Year:

Generation:

Third Generation (RS)

Codes

Platform Code:

NS/RS

👋 Introduction

Market Position

Vehicle Segment:

Minivan

Primary Competitors 2005:

Honda Odyssey, Toyota Sienna, Ford Freestar, Mercury Monterey, Chevrolet Venture, Pontiac Montana, Buick Terraza

Competitive Analysis

Key Selling Points 2005 Caravan:

Versatility, seating capacity, Stow 'n Go seating (introduced later in generation), value for money, availability of all-wheel drive (on some models/years)

Key Features

Stow N Go Seating Availability:

N/A for 2005, introduced in 2005 model year as an option for some trims.

Available Engine Options:

2.4L I4, 3.3L V6, 3.8L V6

Available Drivetrain:

Front-Wheel Drive (FWD), Optional All-Wheel Drive (AWD)

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

All Models/Engines/Trim/Transmissions

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, fuel injection, ignition, cooling, lubrication, exhaust, emissions control

Transmission Systems:

Automatic Transmission (41TE, 42LE), manual transmission (if applicable), clutch, torque converter

Drivetrain Systems:

Front-wheel drive, transaxle, CV joints, drive axles

Brake Systems:

Front and rear brakes (disc/drum), ABS, parking brake

Suspension Systems:

Front suspension (MacPherson strut), rear suspension (Torsion beam axle), steering system

Electrical Systems:

Battery, charging system, starting system, lighting, instrumentation, body controls, power accessories, fuse and relay identification

HVAC Systems:

Heating, Ventilation, and Air Conditioning (HVAC) system operation and diagnosis

Body And Interior:

Body panels, doors, windows, seats, trim, sunroof (if equipped)

Procedures Included

Maintenance Procedures:

Oil changes, fluid checks and replacements, filter replacements, spark plug replacement, belt and hose inspection

Troubleshooting Procedures:

Diagnostic procedures for common and uncommon faults, fault code interpretation

Repair Procedures:

Detailed step-by-step repair instructions for all major systems and components

Diagnosis And Testing:

Component testing, electrical circuit diagnosis, performance testing

Component Replacement:

Instructions for replacing parts such as alternators, starters, water pumps, brake pads, sensors, etc.

Specifications And Tolerances:

Torque specifications, clearances, fluid capacities, diagnostic parameters

Technical Depth

Technical Depth Level:

Comprehensive: Covers basic maintenance to complex diagnostics and full rebuilds

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 2 4L I4:

Displacement 2 4L I4:

2.4 Liters (148 cu in)

Horsepower 2 4L I4:

150 hp @ 5900 rpm

Torque 2 4L I4:

160 lb-ft @ 4100 rpm

Engine Option 2

Engine Code 3 3L V6:

Displacement 3 3L V6:

3.3 Liters (203 cu in)

Horsepower 3 3L V6:

180 hp @ 5000 rpm

Torque 3 3L V6:

205 lb-ft @ 4000 rpm

Engine Option 3

Engine Code 3 8L V6:

Displacement 3 8L V6:

3.8 Liters (230 cu in)

Horsepower 3 8L V6:

205 hp @ 5000 rpm

Torque 3 8L V6:

235 lb-ft @ 3400 rpm

Performance

Engine Type:

SOHC V6, OHV V6, DOHC I4

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Engine Management

Engine Control Module:

Chrysler SBEC or NGC system

🔧 Transmission

Standard

Standard Transmission Type:

4-speed automatic (41TE/42LE)

Optional

Optional Transmission Type:

All-wheel drive system integrated with 4-speed automatic

Features

Transmission Fluid Type:

ATF+4 (MS-9602)

Torque Converter Lockup:

Electronically controlled lockup clutch

📐 Dimensions

Exterior

Wheelbase Short Wheelbase:

112.2 inches (2850 mm)

Wheelbase Long Wheelbase:

119.2 inches (3028 mm)

Overall Length Short Wheelbase:

186.3 inches (4732 mm)

Overall Length Long Wheelbase:

193.3 inches (4909 mm)

Overall Width:

72.0 inches (1829 mm)

Overall Height:

67.8 inches (1722 mm)

Cargo

Max Cargo Volume Behind First Row:

Approx. 149.8 cu ft (SWB), 168.4 cu ft (LWB)

Weights

Curb Weight Range:

3,700 - 4,200 lbs (approx.)

Gross Vehicle Weight Rating Gvwr:

5,700 - 6,000 lbs (approx.)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver Rating:

★★★★ (4-star)

NHTSA Frontal Impact Passenger Rating:

★★★★ (4-star)

NHTSA Side Impact Front Seat Rating:

★★★★ (4-star)

NHTSA Side Impact Rear Seat Rating:

★★★★★ (5-star)

IIHS Frontal Offset Rating:

Acceptable

Active Features

Anti Lock Braking System ABS:

Standard

Traction Control:

Optional (on some models)

Passive Features

Airbags:

Driver and front passenger airbags, optional side airbags

Seat Belts:

3-point seat belts for all occupants, driver and front passenger seatbelt pretensioners

💡 Technology Features

Infotainment

Audio System Options:

AM/FM stereo with CD player, cassette player (early models), optional premium audio systems with subwoofer.

Rear Seat Entertainment:

Optional rear-seat entertainment system (RSE) with DVD player and screens.

Driver Assistance

Cruise Control:

Standard on most trims

Power Sliding Doors And Liftgate:

Optional on many trims

Connectivity

Keyless Entry:

Standard or optional depending on trim level

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months, whichever comes first (synthetic oil recommended for longer intervals)

Engine Air Filter Replacement:

Every 30,000 miles or 24 months

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement 3 3L 3 8L:

Every 100,000 miles (platinum or iridium plugs)

Transmission Fluid Change:

Every 30,000 - 60,000 miles, depending on driving conditions (refer to manual)

Fluid Specifications

Engine Oil Type 2 4L:

SAE 5W-30 (API certified)

Engine Oil Type 3 3L 3 8L:

SAE 5W-30 or 10W-30 (API certified, check owner's manual for specific recommendations based on climate)

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, or equivalent

Brake Fluid Type:

DOT 3

Power Steering Fluid:

ATF+4 (MS-9602) or Mopar Power Steering Fluid

Known Issues

Common Problem Transmission Issues:

Hesitation, slipping, delayed engagement, particularly with the 41TE/42LE transmission. Often related to solenoid pack, valve body, or cooler issues.

Common Problem Engine Mounts:

Premature wear or failure of engine and transmission mounts leading to excessive vibration.

Common Problem Cooling System:

Leaking radiator, heater core, or coolant hoses. Overheating can occur due to these issues.

Common Problem Rear Suspension:

Sagging rear springs, worn shocks/struts, especially under load.

Common Problem Interior Rattles And Squeaks:

Common in minivans of this era due to extensive interior trim and wear.

📚 Vehicle History

Brand Heritage

Chrysler Minivan Legacy:

Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983.

Model Evolution

Generation Introduction Year:

1996 (NS Generation), 2001 (RS Generation - Facelifted NS)

2005 Model Year Updates:

Minor packaging changes, introduction of Stow 'n Go seating as an option on some trims, updated wheel designs.

Production

Manufacturing Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA

🏆 Awards & Recognition

Recognitions

Ward'S 10 Best Engines Award:

The 3.8L V6 engine (L32) was a multiple winner of Ward's 10 Best Engines award in previous years, recognized for its smooth power delivery and refinement.

Ratings

Consumer Reports Reliability Ratings:

Varied by model year and specific components; 2005 models generally received average to below-average reliability ratings, often citing transmission and power accessory issues.