Dodge Grand Caravan Complete Workshop Service Repair Manual 2005

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🏷️ Basic Information Identification Make: Dodge Model: Grand Caravan Year: 2005 Codes Chassis Code: NS 👋 Introduction Market Position Segment: Minivan Usp: Family-oriented, versatile, practical, affordable transportation Competitive Analysis Key...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Grand Caravan

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Minivan

Family-oriented, versatile, practical, affordable transportation

Competitive Analysis

Key Competitors 2005:

Honda Odyssey, Toyota Sienna, Ford Freestar, Chevrolet Uplander, Kia Sedona

Key Features

Interior Versatility:

Stow 'n Go seating (optional on many trims), flexible seating configurations, ample cargo space

Powertrain Options:

Reliable V6 engines, generally good fuel economy for its class

Value Proposition:

Offers a strong feature set and practicality at a competitive price point

📋 Manual Details

Coverage Areas

Geographic Coverage:

North America (USA, Canada, Mexico)

Page Count

Estimated Page Count:

1800+

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing, lubrication system, cooling system, fuel injection, intake manifold, exhaust system

Engine Performance:

Engine diagnostics, performance tuning, emissions control system (OBD-II)

Transmission Manual:

Manual transmission service and repair (if applicable, though typically automatic for Grand Caravan)

Transmission Automatic:

Automatic transmission (41TE/42LE, NAG1 variants) service, overhaul, diagnosis, fluid and filter replacement

Drivetrain:

Front-wheel drive system, axles, CV joints, differential

Suspension Steering:

Front suspension (MacPherson strut), rear suspension (multi-link, trailing arm), shock absorbers, springs, bushings, steering system (power steering pump, rack and pinion, tie rods), alignment specifications

Brakes:

Front and rear disc brakes, ABS system, brake fluid, calipers, rotors, pads, hydraulic lines, parking brake

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition system, lighting (headlights, taillights, interior), horn, wipers, power windows, power locks

Body Chassis:

Body construction, interior trim, exterior trim, doors, hood, tailgate, bumpers, chassis components, corrosion protection

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, compressor, condenser, evaporator, refrigerant, climate control diagnostics

Body Electronics:

Body Control Module (BCM), instrument cluster, interior electronics, remote keyless entry, security system

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, tire rotation, battery maintenance

Troubleshooting:

Diagnostic procedures for all major systems, symptom-based troubleshooting guides, wiring diagrams, diagnostic trouble codes (DTCs)

Repair Overhaul:

Complete step-by-step repair and overhaul procedures for engine, transmission, suspension, brakes, steering, electrical components, and bodywork

Disassembly Assembly:

Detailed instructions for component removal and installation

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical specifications, dimensional data

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable PDF with clear images and diagrams

Print Quality

Printability:

Printable pages for easy workshop use

Binding Type

Binding:

N/A (Downloadable PDF)

Paper Type

Paper Type:

N/A (Downloadable PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EDG (3.3L V6)

Displacement:

3.3 Liters (3301 cc)

Configuration:

SOHC V6

Bore X Stroke:

93.0 mm x 81.0 mm

Compression Ratio:

9.6:1

Performance

Horsepower:

180 hp @ 5000 rpm

Torque:

205 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Fuel Octane Rating:

87 octane minimum

Cooling System

Coolant Capacity:

Approx. 11.0 quarts (10.4 liters) with reservoir

Coolant Type:

Mopar Antifreeze/Coolant (MS-9769) or equivalent (50/50 mix of antifreeze and distilled water)

Lubrication System

Oil Capacity:

4.5 quarts (4.3 liters) with filter

Engine Oil Type:

SAE 5W-30

Oil Filter Part Number Example:

Mopar MO-090 or Wix 57712 (verify fitment)

Optional Engine

Engine Code:

EGA (3.8L V6)

Displacement:

3.8 Liters (3778 cc)

Configuration:

OHV V6

Horsepower:

200 hp @ 5000 rpm

Torque:

230 lb-ft @ 3600 rpm

🔧 Transmission

Standard

Type:

4-speed automatic (41TE/42LE)

Optional

Type:

4-speed automatic (NAG1 - W5A580 on some higher trims or specific powertrains)

Features

Transmission Fluid Type:

ATF+4 (MS-9602)

Transmission Fluid Capacity:

Approx. 3.0-3.7 quarts (2.8-3.5 liters) for drain and fill (check manual for specific fill procedure)

Transmission Filter Part Number Example:

Mopar 04799667AA or Wix 58774 (verify fitment)

📐 Dimensions

Exterior

Length:

199.0 inches (5055 mm)

Width:

71.7 inches (1821 mm)

Height:

68.0 inches (1727 mm)

Wheelbase:

119.0 inches (3023 mm)

Interior

Passenger Volume:

Approx. 145.5 cu ft (4120 liters)

Cargo

Cargo Volume Behind First Row:

Approx. 140.0 cu ft (3965 liters)

Cargo Volume Behind Second Row:

Approx. 77.5 cu ft (2195 liters) with Stow 'n Go

Cargo Volume Behind Third Row:

Approx. 31.5 cu ft (892 liters) with Stow 'n Go

Weights

Curb Weight:

Approx. 4200 - 4400 lbs (1905 - 2000 kg), depending on configuration

Gross Vehicle Weight Rating Gvwr:

Approx. 5700 - 5800 lbs (2585 - 2630 kg)

Towing Capacity:

Up to 3,800 lbs (1724 kg) with optional towing package

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

★★★★★ (5-Star)

NHTSA Front Impact Passenger:

★★★★★ (5-Star)

NHTSA Side Impact Front Seat:

★★★★☆ (4-Star)

NHTSA Side Impact Rear Seat:

★★★★☆ (4-Star)

IIHS Frontal Offset Score:

IIHS Side Impact Score:

Acceptable

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional (often linked with Electronic Stability Program in later years)

Electronic Stability Control:

Optional (often part of the 'ESC' or 'ESP' package, sometimes called 'Active Stability Control')

Passive Features

Airbags Front:

Standard multi-stage front airbags

Airbags Side:

Optional front-seat mounted side airbags, optional side curtain airbags (may be trim dependent)

Seatbelts:

Three-point seat belts in all seating positions, pretensioners for front seats

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player, optional Infinity premium audio system, optional rear-seat entertainment system

Navigation:

Optional factory navigation system (very basic by modern standards)

Driver Assistance

Parking Sensors:

Optional rear park assist sensors

Connectivity

Remote Keyless Entry:

Standard or optional, depending on trim level

Power Features:

Power windows, power door locks, power sliding doors (optional), power tailgate (optional)

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type used. Consult manual for exact recommendation.

Air Filter Replacement:

Every 12,000-15,000 miles (19,000-24,000 km) or annually. Inspect more frequently.

Transmission Fluid Filter Change:

Every 30,000-60,000 miles (48,000-96,000 km), depending on usage. Crucial for automatic transmission longevity.

Coolant Flush And Replace:

Every 30,000 miles (48,000 km) or 2 years.

Spark Plug Replacement:

3.3L V6 (EDG): Approx. 100,000 miles (160,000 km) with platinum plugs. 3.8L V6 (EGA): Approx. 60,000-100,000 miles (96,000-160,000 km) depending on plug type. Consult manual.

Fluid Specifications

Power Steering Fluid:

ATF+4 (MS-9602) or Mopar Power Steering Fluid (MS-5901)

Brake Fluid:

DOT 3

Known Issues

Transmission Hard Shifts:

Common in 41TE/42LE transmissions; often related to solenoid pack issues or fluid contamination. The manual details diagnosis and repair.

Engine Oil Leaks:

Can occur from valve cover gaskets, oil pan gaskets, or crank seals. Manual provides detailed replacement procedures.

Sway Bar Links And Bushings:

Wear over time, leading to clunking noises over bumps. Covered in suspension section.

Power Sliding Doors:

Can experience issues with motors, latches, or control modules. Manual provides diagnostic steps.

Rear Wiper Failure:

Common issue with the motor or linkage. Manual details removal and replacement.

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge pioneered the minivan segment with the original Caravan/Grand Caravan in 1984, establishing it as a leader in family transportation.

Model Evolution

Fourth Generation:

The 2005 Grand Caravan is part of the fourth generation (2001-2007) of the Dodge Caravan platform, which saw significant redesigns in styling and features.

Facelift 2005:

The 2005 model year received a mid-generation refresh, including updated styling (grille, headlights, taillights), improved interior materials, and the introduction/enhancement of features like Stow 'n Go seating.

Production

Manufacturing Location:

Windsor, Ontario, Canada (Chrysler Canada Assembly Plant)

🏆 Awards & Recognition

Recognitions

Family Car Awards:

The Grand Caravan has historically been a strong contender in family vehicle awards due to its practicality and value. Specific awards for 2005 vary, but its segment was often recognized.

Ratings

Kbb Value Rating:

Good resale value for its segment, especially in well-maintained condition.

Certifications

Federal Safety Certification:

Complies with all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for 2005 models.