🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

2005

Engine Type:

Diesel

Platform:

NS (North America)

👋 Introduction

Vehicle Segment:

Minivan

Target Audience:

Families, fleet operators seeking a versatile and economical people carrier.

Key Competitors:

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

Vehicle Strengths:

Spacious interior, versatile seating configurations, comfortable ride, and the distinctive torque and fuel efficiency of the turbodiesel engine option.

Manual Value Proposition:

Empowers owners and independent repair shops with factory-level diagnostic and repair information for the specific diesel variant, a less common powertrain in this model year.

📋 Manual Details

Engine Coverage:

Comprehensive diagnosis, repair, and overhaul of the 2.8L VM Motori CRD turbodiesel engine.

Transmission Coverage:

Detailed procedures for the 4-speed automatic transmission (42LE).

Chassis Coverage:

Suspension, steering, brakes (including ABS), wheels, and tires.

Electrical Coverage:

Complete wiring diagrams, diagnostics for all electrical systems, including lighting, power accessories, engine control module (ECM), and instrument cluster.

Body Coverage:

Interior and exterior body repair, doors, windows, bumpers, and trim.

HVAC Coverage:

Air conditioning, heating, and ventilation system diagnostics and repair.

Safety Systems Coverage:

Airbag system diagnostics and repair.

Total Pages:

Approx. 1500-2000 pages (estimated for comprehensive factory manual).

Type:

Factory Service Manual

Language:

English

Format:

Digital (PDF or similar, searchable)

📖 Manual Coverage

Powertrain Systems:

Engine mechanical, engine electrical, fuel system (common rail injection), exhaust system, cooling system, lubrication system, turbocharger system, engine control system (ECM).

Drivetrain Systems:

Transmission (automatic), driveshafts, axles, differentials.

Braking Systems:

Front and rear brakes (disc/drum), parking brake, ABS (Anti-lock Braking System) diagnostics and repair.

Suspension Steering Systems:

Front and rear suspension components (struts, springs, control arms, bushings), steering gear, power steering system, alignment specifications.

Fuel System:

High-pressure common rail injection system, fuel pump, injectors, fuel filter replacement, fuel pressure testing.

Cooling System:

Radiator, thermostat, water pump, cooling fan operation, coolant type and capacity.

Lubrication System:

Oil pump, oil filter replacement, oil type and capacity, oil pressure testing.

Electrical And Electronic Systems:

Battery, charging system (alternator), starting system (starter motor), lighting circuits, instrument cluster, body control module (BCM), immobilizer system, diagnostic connectors (OBD-II).

Maintenance Procedures:

Oil and filter changes, air filter replacement, fuel filter replacement, coolant flush and fill, spark plug (glow plug) replacement, brake fluid flush.

Repair Procedures:

Engine component replacement (e.g., injectors, glow plugs, turbocharger, EGR valve), transmission overhaul, brake caliper replacement, suspension component replacement, power steering pump replacement.

Diagnostic Procedures:

Troubleshooting charts, fault code interpretation (P-codes, manufacturer-specific codes), component testing (resistance, voltage, current), pressure testing (fuel, oil).

Assembly Disassembly:

Step-by-step instructions for removing and installing major components.

Torque Specifications:

Detailed torque values for critical fasteners throughout the vehicle.

Depth:

Comprehensive. Covers basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

Digital Format Features:

Searchable text, hyperlinked sections, high-resolution diagrams, zoom functionality.

Diagram Quality:

High-resolution, clear, and accurate diagrams with callouts.

Text Readability:

Easy-to-read font and layout.

Binding:

N/A (digital format)

Paper Quality:

N/A (digital format)

⚙️ Engine Specifications

Engine Code:

R428 (2.8L CRD)

Engine Description:

2.8-liter inline 4-cylinder turbocharged common rail direct injection diesel engine.

Displacement:

2768 cc (168.9 cu in)

Bore X Stroke:

94.0 mm x 100.0 mm (3.70 in x 3.94 in)

Compression Ratio:

18.5:1

Valvetrain:

SOHC (Single Overhead Camshaft), 4 valves per cylinder (16 valves total)

Fuel Delivery System:

Bosch High-Pressure Common Rail (HPCR) direct injection

Turbocharger:

Variable Geometry Turbocharger (VGT) with intercooler

Horsepower:

150 hp @ 3800 rpm (approx.)

Torque:

295 lb-ft @ 1800 rpm (approx.)

Fuel Type:

Diesel

Fuel Injection Pressure:

Up to 1600 bar (23,200 psi)

🔧 Transmission

Transmission Type:

4-speed Automatic

Transmission Model:

42LE

Transmission Control:

Electronic with adaptive shifting.

Transmission Fluid Type:

ATF+4 (Chrysler)

Transmission Fluid Capacity:

Approx. 9.5 - 10.5 quarts (9.0 - 9.9 liters) for a dry fill.

📐 Dimensions

Wheelbase:

Approx. 119.9 inches (3045 mm)

Length:

Approx. 189.4 inches (4811 mm)

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 68.0 inches (1727 mm)

Cargo Volume Behind 3Rd Row:

Approx. 15.2 cu ft (430 liters)

Cargo Volume With 3Rd Row Folded:

Approx. 74.1 cu ft (2098 liters)

Cargo Volume With 2Nd And 3Rd Rows Removed:

Approx. 140.5 cu ft (3978 liters)

Curb Weight:

Approx. 4300-4600 lbs (1950-2087 kg), varies by configuration.

Gross Vehicle Weight Rating Gvw:

Approx. 6150 lbs (2790 kg)

🛡️ Safety Features

NHTSA Front Crash Test Rating:

Good (for driver and passenger in frontal offset test, 2005 model year testing).

NHTSA Side Crash Test Rating:

Not rated (for 2005 model year, side impact testing protocols may differ).

IIHS Offset Crash Test Rating:

Acceptable (for 2005 model year).

ABS:

Standard (Anti-lock Braking System)

Traction Control:

Optional (TCS)

Airbags:

Standard front driver and passenger airbags. Optional side curtain airbags (check specific vehicle configuration).

Seat Belts:

3-point seat belts with pretensioners in all seating positions.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player. Optional rear-seat entertainment systems available on some trims.

Cruise Control:

Standard

Parking Assistance:

Rear parking assist sensors optional on higher trims.

Power Accessories:

Power windows, power door locks, and power sliding doors (optional on some trims).

🔧 Maintenance

Engine Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first, using the specified oil.

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Fuel Filter Replacement:

Every 30,000 miles (48,000 km).

Transmission Fluid Change Interval:

Every 60,000 miles (96,000 km) or 48 months, under normal driving conditions. Severe service may require more frequent changes.

Coolant Replacement Interval:

Initial change at 100,000 miles (160,000 km) or 5 years, then every 50,000 miles (80,000 km) or 3 years.

Timing Belt Replacement:

N/A (This engine uses a timing chain).

Engine Oil Specification:

API CJ-4 or ACEA E7/E9 synthetic diesel engine oil, SAE 5W-40 is recommended. Check owner's manual for specific viscosity and certification requirements.

Engine Oil Capacity:

Approx. 6.5 quarts (6.2 liters) with filter change.

Coolant Type:

Chrysler OAT (Organic Additive Technology) or equivalent HOAT coolant (typically orange or red).

Common Problems Diesel:

Injectors can be prone to clogging with poor fuel quality. EGR valve and turbocharger may require cleaning or replacement due to carbon buildup. Glow plug issues can affect cold starts. Potential for cracked cylinder heads on early CRD engines if overheated.

Transmission Issues:

The 42LE transmission can experience hard shifts or slippage if fluid is not maintained or if the valve body is contaminated. Torque converter lock-up issues can also occur.

Suspension Wear:

Front suspension components like ball joints and bushings can wear over time, leading to clunking noises and alignment issues.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan and Voyager in the mid-1980s, establishing a benchmark for family transportation.

Fourth Generation Ns:

The 2005 Caravan is part of the fourth generation (NS) of the Dodge Caravan, introduced for the 2001 model year, featuring updated styling, chassis, and powertrains.

Diesel Powertrain Introduction:

The VM Motori 2.8L CRD turbodiesel engine was a significant option for the fourth-generation Caravan, offering enhanced fuel economy and torque compared to gasoline counterparts, particularly popular in European and some North American markets.

Manufacturing Locations:

Primarily Windsor, Ontario, Canada; Saltillo, Mexico.

🏆 Awards & Recognition

Minivan Segment Popularity:

The Dodge Caravan has historically been a segment leader in sales and popularity due to its practicality and value. While specific awards for the 2005 diesel variant are scarce, the model line consistently ranked well for family transport.