Chrysler Caravan 2005-2007 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Generation: Fourth Generation (RS) Codes Platform Code: NS/GS (shared with Plymouth Voyager, Dodge Caravan, Dodge Grand Caravan) 👋 Introduction Market Position Segment: Minivan Target Audience: Families, commercial users, DIY mechanics Competitive Analysis Key Competitors Era: Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Venture/Uplander Key Features Vehicle Strengths: Spacious interior, flexible seating, available all-wheel drive (AWD), Stow 'n Go seating (introduced in later models of this generation, but predecessor featured similar versatility) Manual Value Proposition: Provides comprehensive DIY repair and maintenance guidance, saving on dealership costs and enabling informed decision-making. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007 Region Applicability: North America (primarily US, Canada, Mexico) Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive service manuals of this era) Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital (PDF) - likely searchable and printable 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine performance, fuel system, exhaust system, cooling system, lubrication system Transmission Drivetrain: Automatic transmission (41TE/42LE), manual transmission (if applicable to specific trims), driveline components, axles, driveshafts Chassis Suspension: Front suspension, rear suspension, steering system, braking system (ABS, rear drum/disc) Electrical Electronics: Body control module (BCM), Powertrain Control Module (PCM), ignition system, lighting, instruments, comfort and convenience systems, power accessories, charging system, starting system Body Exterior: Body panels, doors, windows, sunroof, exterior trim, bumpers, hood, liftgate Body Interior: Seats, interior trim panels, dashboard, HVAC system (heating, ventilation, air conditioning), audio system, airbags Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Repair Overhaul: Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical component diagnosis and repair Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical schematic interpretation, component testing Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters Technical Depth Depth: Comprehensive: Covers routine maintenance to major component overhaul and advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable (if digitally created from source material) Print Quality Print Readability: High (designed for clear printing of text and diagrams) Binding Type Binding: N/A (digital format, but originally printed manuals would be bound) Paper Type Paper Quality: N/A (digital format, but original manuals used durable paper) ⚙️ Engine Specifications Primary Engine Engine Code Common: EGA (3.3L V6 OHV) Displacement Liters: 3.3 Cylinders: 6 Engine Type: V6 Valvetrain: Overhead Valve (OHV), 12 valves (2 valves per cylinder) Horsepower Hp Approx: 180 - 185 hp Torque Lb Ft Approx: 205 - 210 lb-ft Performance Fuel Type: Unleaded gasoline Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Engine Variations Optional Engine 2: EDZ (3.8L V6 OHV) - less common in this specific timeframe for Caravan, more for Grand Caravan, but possible Displacement Liters Optional: 3.8 🔧 Transmission Standard Type: 4-speed Automatic Transaxle Model Code Common: 41TE (FWD), 42LE (AWD) Optional Type: All-Wheel Drive (AWD) Features Overdrive Gears: Yes, 4 forward gears with overdrive Fluid Specifications Transmission Fluid Type: ATF+4 (Chrysler Material Standard MS-9602) Fluid Capacities Transmission Fluid Capacity Quarts: Approx. 4.5 quarts (dry fill) 📐 Dimensions Exterior Wheelbase Inches: Approx. 113.3 inches Length Inches Approx: 189.4 inches Width Inches Approx: 72.0 inches Height Inches Approx: 67.8 inches Cargo Cargo Volume Behind 3Rd Row Cu Ft: Approx. 25.0 - 30.0 cu ft (depending on configuration) Cargo Volume Max Cu Ft: Approx. 140.0 - 150.0 cu ft (with rear seats removed) Weights Curb Weight Lbs Approx: 4000 - 4300 lbs (depending on configuration) Towing Capacity Lbs Approx: Up to 3800 lbs (with optional towing package) 🛡️ Safety Features Ratings NHTSA Front Impact Driver Stars: 4 Stars (for 2005-2007 models in frontal crash tests) NHTSA Front Impact Passenger Stars: 5 Stars (for 2005-2007 models in frontal crash tests) NHTSA Side Impact Front Seat Stars: 4 Stars NHTSA Side Impact Rear Seat Stars: 4 Stars Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional (often bundled with AWD or higher trims) Passive Features Airbags: Standard front airbags; optional side curtain airbags (later in the generation) Seat Belts: Height-adjustable front seat belts, all seating positions equipped with three-point seat belts 💡 Technology Features Infotainment Audio Systems: AM/FM stereo with CD player, optional cassette player, premium speaker systems available. Rear Seat Entertainment: Optional rear-seat entertainment systems (RSE) with DVD players were available on higher trims. Driver Assistance Cruise Control: Standard cruise control. Parking Assist: Rear parking assist sensors were an available option. Connectivity Auxiliary Input: Typically not standard; aftermarket solutions often needed for audio input. 🔧 Maintenance Service Intervals Oil Change Miles Typical: Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type (consult manual for specific recommendations). Tire Rotation Miles: Every 6,000-8,000 miles Transmission Fluid Change Miles: Every 30,000-60,000 miles, depending on driving conditions (crucial for ATF+4). Coolant Flush Miles: Every 30,000-60,000 miles or...
NS/GS (shared with Plymouth Voyager, Dodge Caravan, Dodge Grand Caravan)
👋 Introduction
Market Position
Segment:
Minivan
Target Audience:
Families, commercial users, DIY mechanics
Competitive Analysis
Key Competitors Era:
Honda Odyssey, Toyota Sienna, Ford Freestar/Windstar, Chevrolet Venture/Uplander
Key Features
Vehicle Strengths:
Spacious interior, flexible seating, available all-wheel drive (AWD), Stow 'n Go seating (introduced in later models of this generation, but predecessor featured similar versatility)
Manual Value Proposition:
Provides comprehensive DIY repair and maintenance guidance, saving on dealership costs and enabling informed decision-making.
📋 Manual Details
Coverage Areas
Years Covered:
2005, 2006, 2007
Region Applicability:
North America (primarily US, Canada, Mexico)
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for comprehensive service manuals of this era)
Automatic transmission (41TE/42LE), manual transmission (if applicable to specific trims), driveline components, axles, driveshafts
Chassis Suspension:
Front suspension, rear suspension, steering system, braking system (ABS, rear drum/disc)
Electrical Electronics:
Body control module (BCM), Powertrain Control Module (PCM), ignition system, lighting, instruments, comfort and convenience systems, power accessories, charging system, starting system
Body Exterior:
Body panels, doors, windows, sunroof, exterior trim, bumpers, hood, liftgate
Body Interior:
Seats, interior trim panels, dashboard, HVAC system (heating, ventilation, air conditioning), audio system, airbags
Torque converter shudder in automatic transmissions, occasional EGR valve issues on older engines, potential coolant leaks from plastic components.
Common Problems Electrical:
Power window motor failures, HVAC blower motor resistor issues, intermittent electronic module failures (e.g., TIPM - Totally Integrated Power Module).
Common Problems Chassis:
Worn sway bar links and bushings, rear axle bearing noise, front suspension component wear (ball joints, tie rods).
Common Problems Body:
Liftgate strut failure, sliding door mechanism issues, rust in common minivan areas (wheel wells, rocker panels).
📚 Vehicle History
Brand Heritage
Chrysler Legacy:
Chrysler has a long history of innovation in the automotive industry, particularly known for its advancements in minivan technology.
Model Evolution
Minivan Pioneer:
Chrysler is credited with pioneering the modern minivan segment with the original Dodge Caravan and Plymouth Voyager in the 1980s. The Caravan nameplate continued this legacy.
Generation Timeline:
This 2005-2007 period represents the latter part of the fourth generation (RS) minivan platform, which saw significant updates and refinements over its lifespan (1996-2007).
Production
Manufacturing Location:
Windsor, Ontario, Canada (primarily for North American market)
Production Years Generation:
1996-2007
🏆 Awards & Recognition
Recognitions
Konsumen Reports Ratings:
Consumer Reports often provided mixed reviews for this generation, citing reliability concerns in certain areas while praising its practicality and value.
IIHS Ratings:
Good in frontal offset crash tests (IIHS Top Safety Pick potential depending on specific year and testing criteria).
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