Chrysler Caravan 2005 2006 2007 Repair Service Manual

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🏷️ Basic Information Identification Make: Chrysler Model: Caravan Model Generation: Fourth Generation (RS) Model Years Covered: 2005, 2006, 2007 Codes Chassis Code: RS 👋 Introduction Market Position Segment: Minivan Target Audience: Families, fleet operators, DIY mechanics, professional technicians. Competitive Analysis Key Competitors Model Years: 2005-2007: Honda Odyssey, Toyota Sienna, Ford Freestar, Mercury Monterey, Nissan Quest. Key Features Vehicle Sliding Doors: Signature feature providing easy access for passengers and cargo. Versatile Seating: Stow 'n Go seating (optional on some trims) or traditional fold-flat/removable seats offering flexible cargo configurations. Powertrain Options: Reliable V6 engines known for their torque and towing capability. Key Features Manual Completeness: Comprehensive coverage designed to assist with virtually all service and repair needs. Clarity: Clear, concise language and detailed diagrams facilitate understanding for technicians of all skill levels. Diagnostic Focus: Strong emphasis on diagnostic procedures to efficiently identify and resolve issues. 📋 Manual Details Coverage Areas Primary Coverage: North America (USA, Canada, Mexico) Region Specific Variants: Includes information relevant to North American specifications and emissions standards. Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, diagnostics, component testing, timing, lubrication, cooling system. Engine Performance: Fuel delivery, ignition system, emissions control, exhaust system, intake manifold. Transmission Automatic: 4-speed Automatic Transaxle (e.g., 41TE, 42LE variations), hydraulic controls, valve body, torque converter, fluid service. Transmission Manual: Coverage for manual transmissions, if equipped (less common on this model). Drivetrain: Front-wheel drive, axle shafts, CV joints, differential. Brakes: Hydraulic system, ABS, disc brakes, drum brakes, parking brake, component replacement, bleeding procedures. Suspension: Front suspension (MacPherson struts), rear suspension (torsion beam or multi-link depending on configuration), shock absorbers, springs, ball joints, bushings. Steering: Power steering system, steering column, rack and pinion, tie rods. Electrical System: Battery, starting system, charging system (alternator), wiring diagrams, fuses, relays. Lighting: Headlights, taillights, interior lighting, bulb replacement. Body And Frame: Body panel removal/installation, door mechanisms, glass, interior trim, underbody. Climate Control: HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls. Interior Systems: Seats, seatbelts, airbags, dashboard components, audio system, power windows/locks. Diagnostics And Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, diagnostic tool usage. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and changes, belt inspection/replacement, spark plug service. Repair Procedures: Detailed step-by-step instructions for component replacement and repair across all systems. Troubleshooting Guides: Systematic approaches to diagnosing and resolving common and uncommon faults. Specifications And Tolerances: Torque values, clearances, fluid capacities, diagnostic specifications. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Special Tools: Identification and usage of specialized tools required for certain repairs. Technical Depth Depth: Comprehensive (from basic maintenance to major component overhaul and diagnostics). Diagnostic Capability: Advanced diagnostic procedures, including scan tool data interpretation and sensor testing. Rebuild Instructions: Detailed instructions for rebuilding key components like engines and transmissions. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable (allows quick finding of specific terms and sections). Printability: Printable (allows users to print specific pages or the entire manual). Print Quality Image Resolution: High-resolution scans/digital reproductions for clear diagrams and text. Binding Type Binding: N/A (Digital PDF Format) Paper Type Paper Quality: N/A (Digital PDF Format) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 3.3L V6 (EGA) / 3.8L V6 (L32) Displacement 3.3L: 3.3 Liters (3301 cc) Displacement 3.8L: 3.8 Liters (3778 cc) Configuration: Overhead Valve (OHV) V6 Performance Horsepower 3.3L: Approx. 180-185 hp @ 4500-5000 rpm Torque 3.3L: Approx. 210-220 lb-ft @ 3000-3200 rpm Horsepower 3.8L: Approx. 200-205 hp @ 4800-5000 rpm Torque 3.8L: Approx. 230-240 lb-ft @ 3200-3400 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane minimum recommended) Emission Controls: California Emission System (Optional, depending on state of sale). 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transaxle Optional Manual Transmission Availability: Not typically offered or very rare on these model years and platform. Features Transmission Control: Electronic automatic transmission with Park/Neutral/Drive/Low gear selections. Fluid Specifications Transmission Fluid Type: ATF+4 (Automatic Transmission Fluid, Type 9602) Fluid Capacities Transmission Fluid Capacity Dry Fill: Approx. 7.5 - 8.0 quarts (7.1 - 7.6 liters) Gear Ratios Typical Gear Ratios: Refer to manual for specific ratios of 41TE/42LE variants. 📐 Dimensions Exterior Length: Approx. 190.3 - 201.7 inches (4834 - 5123 mm), depending on wheelbase. Width: Approx. 72.0 inches (1829 mm) Height: Approx. 68.2 inches (1732 mm) Wheelbase: Approx. 112.1 inches (2847 mm) / 119.4 inches (3033 mm) for Grand Caravan Interior Passenger Capacity: 7 passengers (standard configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 20-30 cubic feet (variable by configuration) Cargo Volume Max: Approx. 140-160 cubic feet (with rear seats removed/folded) Weights Curb Weight: Approx. 4,000 - 4,500 lbs (1814 - 2041 kg), depending on configuration. Gross Vehicle Weight Rating Gvwr: Approx. 5,700...

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Taper: Car

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UGS: 565967

Collections: ALL Chrysler Marine

Disponibilité: En stock

Mots clés: 2005 2006 2007 Car Caravan Chrysler Marine Misc Outboard Engines

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Chrysler

Model:

Caravan

Model Generation:

Fourth Generation (RS)

Model Years Covered:

2005, 2006, 2007

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, fleet operators, DIY mechanics, professional technicians.

Competitive Analysis

Key Competitors Model Years:

2005-2007: Honda Odyssey, Toyota Sienna, Ford Freestar, Mercury Monterey, Nissan Quest.

Key Features Vehicle

Sliding Doors:

Signature feature providing easy access for passengers and cargo.

Versatile Seating:

Stow 'n Go seating (optional on some trims) or traditional fold-flat/removable seats offering flexible cargo configurations.

Powertrain Options:

Reliable V6 engines known for their torque and towing capability.

Key Features Manual

Completeness:

Comprehensive coverage designed to assist with virtually all service and repair needs.

Clarity:

Clear, concise language and detailed diagrams facilitate understanding for technicians of all skill levels.

Diagnostic Focus:

Strong emphasis on diagnostic procedures to efficiently identify and resolve issues.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America (USA, Canada, Mexico)

Region Specific Variants:

Includes information relevant to North American specifications and emissions standards.

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, diagnostics, component testing, timing, lubrication, cooling system.

Engine Performance:

Fuel delivery, ignition system, emissions control, exhaust system, intake manifold.

Transmission Automatic:

4-speed Automatic Transaxle (e.g., 41TE, 42LE variations), hydraulic controls, valve body, torque converter, fluid service.

Transmission Manual:

Coverage for manual transmissions, if equipped (less common on this model).

Drivetrain:

Front-wheel drive, axle shafts, CV joints, differential.

Brakes:

Hydraulic system, ABS, disc brakes, drum brakes, parking brake, component replacement, bleeding procedures.

Suspension:

Front suspension (MacPherson struts), rear suspension (torsion beam or multi-link depending on configuration), shock absorbers, springs, ball joints, bushings.

Steering:

Power steering system, steering column, rack and pinion, tie rods.

Electrical System:

Battery, starting system, charging system (alternator), wiring diagrams, fuses, relays.

Lighting:

Headlights, taillights, interior lighting, bulb replacement.

Body And Frame:

Body panel removal/installation, door mechanisms, glass, interior trim, underbody.

Climate Control:

HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls.

Interior Systems:

Seats, seatbelts, airbags, dashboard components, audio system, power windows/locks.

Diagnostics And Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, diagnostic tool usage.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, belt inspection/replacement, spark plug service.

Repair Procedures:

Detailed step-by-step instructions for component replacement and repair across all systems.

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common and uncommon faults.

Specifications And Tolerances:

Torque values, clearances, fluid capacities, diagnostic specifications.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

Special Tools:

Identification and usage of specialized tools required for certain repairs.

Technical Depth

Depth:

Comprehensive (from basic maintenance to major component overhaul and diagnostics).

Diagnostic Capability:

Advanced diagnostic procedures, including scan tool data interpretation and sensor testing.

Rebuild Instructions:

Detailed instructions for rebuilding key components like engines and transmissions.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Text-searchable (allows quick finding of specific terms and sections).

Printability:

Printable (allows users to print specific pages or the entire manual).

Print Quality

Image Resolution:

High-resolution scans/digital reproductions for clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF Format)

Paper Type

Paper Quality:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline:

3.3L V6 (EGA) / 3.8L V6 (L32)

Displacement 3.3L:

3.3 Liters (3301 cc)

Displacement 3.8L:

3.8 Liters (3778 cc)

Configuration:

Overhead Valve (OHV) V6

Performance

Horsepower 3.3L:

Approx. 180-185 hp @ 4500-5000 rpm

Torque 3.3L:

Approx. 210-220 lb-ft @ 3000-3200 rpm

Horsepower 3.8L:

Approx. 200-205 hp @ 4800-5000 rpm

Torque 3.8L:

Approx. 230-240 lb-ft @ 3200-3400 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane minimum recommended)

Emission Controls:

California Emission System (Optional, depending on state of sale).

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic Transaxle

Optional

Manual Transmission Availability:

Not typically offered or very rare on these model years and platform.

Features

Transmission Control:

Electronic automatic transmission with Park/Neutral/Drive/Low gear selections.

Fluid Specifications

Transmission Fluid Type:

ATF+4 (Automatic Transmission Fluid, Type 9602)

Fluid Capacities

Transmission Fluid Capacity Dry Fill:

Approx. 7.5 - 8.0 quarts (7.1 - 7.6 liters)

Gear Ratios

Typical Gear Ratios:

Refer to manual for specific ratios of 41TE/42LE variants.

📐 Dimensions

Exterior

Length:

Approx. 190.3 - 201.7 inches (4834 - 5123 mm), depending on wheelbase.

Width:

Approx. 72.0 inches (1829 mm)

Height:

Approx. 68.2 inches (1732 mm)

Wheelbase:

Approx. 112.1 inches (2847 mm) / 119.4 inches (3033 mm) for Grand Caravan

Interior

Passenger Capacity:

7 passengers (standard configuration)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 20-30 cubic feet (variable by configuration)

Cargo Volume Max:

Approx. 140-160 cubic feet (with rear seats removed/folded)

Weights

Curb Weight:

Approx. 4,000 - 4,500 lbs (1814 - 2041 kg), depending on configuration.

Gross Vehicle Weight Rating Gvwr:

Approx. 5,700 - 6,000 lbs (2585 - 2721 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating Driver:

Good (5-star)

NHTSA Frontal Crash Rating Passenger:

Good (5-star)

NHTSA Side Impact Rating Front Seat:

Good (5-star)

NHTSA Side Impact Rating Rear Seat:

Good (5-star)

IIHS Frontal Offset Rating:

Acceptable/Good (depending on specific test year and configuration)

Active Features

Anti Lock Brakes ABS:

Standard

Traction Control TCS:

Available on some models/trims.

Electronic Stability Control Esc:

Not standard on all models/trims for these years; check specific vehicle.

Passive Features

Airbags Front:

Driver and front passenger airbags standard.

Airbags Side Curtain:

Available as an option on some trims for enhanced head protection.

Seatbelts:

3-point seatbelts for all passengers, height-adjustable front belts.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Infinity audio systems, rear entertainment system (DVD player and screens) available on some trims.

Navigation:

Factory navigation systems were optional on higher trims, typically with a touchscreen interface.

Driver Assistance

Parking Assist:

Rear parking assist sensors were optional on some models.

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Input:

Not commonly equipped with standard auxiliary input jacks; aftermarket solutions may be available.

Remote Keyless Entry:

Standard on most trims.

Power Accessories:

Power windows, power door locks, power mirrors standard or optional depending on trim level.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first (refer to manual for specific recommendations based on driving conditions).

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter:

Replace annually or every 15,000 miles (24,000 km).

Spark Plugs 3.3L:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Spark Plugs 3.8L:

Approx. 100,000 miles (160,000 km) with platinum-tipped plugs.

Transmission Fluid Change:

Every 30,000 to 60,000 miles (48,000 to 96,000 km), or more frequently under severe usage. ATF+4 is considered a 'fill for life' fluid by some but regular checks and changes are recommended by many technicians.

Coolant Change:

Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) thereafter.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (or 5W-20 for some applications, refer to manual and oil cap)

Engine Oil Capacity:

Approx. 4.0-4.5 quarts (3.8-4.3 liters) for 3.3L; 4.5-5.0 quarts (4.3-4.7 liters) for 3.8L (refer to manual and dipstick).

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant (Mopar brand recommended)

Brake Fluid Type:

DOT 3

Power Steering Fluid:

ATF+4 (check manual for confirmation, as some older Chrysler vehicles used dedicated PS fluid).

Known Issues

Transmission Hard Shifting:

Can occur due to worn solenoids, valve body issues, or low fluid pressure. Manual covers diagnosis.

Engine Oil Leaks:

Common areas include valve cover gaskets, oil pan gaskets, and crankshaft seals. Manual details replacement procedures.

Rear Suspension Noise:

Worn bushings or shock absorbers can cause clunking or rattling noises. Manual provides inspection and replacement steps.

Power Sliding Door Failure:

Electrical faults, motor wear, or track issues can lead to malfunction. Manual aids in diagnosing electrical and mechanical problems.

Evaporative Emissions System Faults:

Canister purge valve or vent solenoid issues often trigger Check Engine Lights (CEL). Manual guides diagnosis.

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Group LLC (part of DaimlerChrysler AG during these years).

Model Evolution

Segment Introduction:

Chrysler revolutionized the minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. The Caravan nameplate has been a cornerstone of the American minivan market for decades.

Fourth Generation Debut:

The RS generation debuted for the 2001 model year and received significant updates through its lifecycle, including styling refreshes and feature enhancements.

Specific Year Changes 05 07:

Minor updates and package changes occurred across these years, focusing on safety features and interior refinements. The introduction of the 'Stow 'n Go' seating was a significant feature for the fourth generation.

Production

Manufacturing Locations:

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

Production Period:

2001-2007 (Fourth Generation)

🏆 Awards & Recognition

Recognitions

Car And Driver Editors Choice:

Car and Driver magazine often recognized the minivan segment for its practicality, and the Caravan was a frequent consideration.

Konsumen Reports Ratings:

Consumer Reports typically provided ratings based on predicted reliability, owner satisfaction, and road tests. The Caravan's ratings varied across these model years, often influenced by transmission performance.

Ratings

Safety Awards NHTSA:

Achieved 5-star ratings in frontal and side-impact crash tests from NHTSA for these model years.