🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2005 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Mid-size minivan. Target Audience: Families, fleet operators, DIY mechanics, professional technicians. Competitive Analysis Key Competitors: Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture/Montana. Key Features Vehicle Selling Points: Versatility, passenger and cargo capacity, practicality, available Stow 'n Go seating (later models, but Caravan platform known for this). 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive repair and maintenance information for the 2005 Dodge Caravan. Page Count Page Count: Estimated 1500-2000 pages (typical for this era's comprehensive factory manuals) Manual Type Manual Type: Factory Service Manual / Repair Manual Manual Completeness: Complete, factory-issued documentation, not a condensed Haynes or Chilton style manual. Language Language: English Format Format: Digital (PDF likely, though print copies existed) File Format Quality: High-resolution scans or digital native files ensuring clarity and readability of diagrams and text. Searchability: Likely searchable PDF text, allowing for quick keyword-based information retrieval. 📖 Manual Coverage Systems Covered Engine Diagnostics: Detailed troubleshooting, component testing, specifications for all engine variants. Engine Mechanical: Engine removal/installation, cylinder head, piston, crankshaft, camshaft, timing, lubrication, cooling system overhaul. Fuel System: Fuel delivery, fuel injection system (MPI), fuel tank, lines, filters, pressure testing, component testing. Ignition System: Ignition coil, spark plugs, wiring, diagnostic procedures, timing specifications. Transmission Automatic: Removal/installation, internal component overhaul, torque converter, valve body, solenoids, fluid service, diagnostic codes. Transmission Manual: Removal/installation, internal component overhaul, clutch, flywheel, diagnostic procedures. Drivetrain: Axles, CV joints, drive shafts, differential, wheel bearings, hub assemblies. Brakes: Front and rear brake systems, caliper, pads, rotors, lines, master cylinder, ABS system components and diagnostics. Suspension: Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), alignment specifications. Steering: Power steering system, pump, rack and pinion, steering column, linkage, components and diagnostics. Electrical System: Battery, charging system, starter, alternator, wiring diagrams for all circuits, fuses, relays. Lighting System: Headlights, taillights, interior lights, bulb specifications, wiring. HVAC System: Air conditioning, heating, ventilation, blower motor, compressor, evaporator, condenser, refrigerant, troubleshooting. Body And Chassis: Body panel removal/installation, door mechanisms, glass, interior trim, exterior trim, frame structure. Restraints: Airbag system components, SRS module, seat belts, diagnostic procedures. Diagnostic Troubleshooting: Systematic approaches, symptom-based troubleshooting, diagnostic trouble codes (DTCs). Procedures Included Scheduled Maintenance: Detailed procedures for oil changes, filter replacements, fluid checks, tire rotations, belt inspections. Component Replacement: Step-by-step instructions for replacing major and minor components across all systems. Diagnostic Procedures: Methods for identifying faults using scan tools, multimeters, and visual inspections. Rebuilding Procedures: Instructions for overhauling engines, transmissions, and other major mechanical units. Specifications Torque Values: Precise torque specifications for all fasteners, critical for proper assembly. Technical Depth Depth Of Coverage: Extremely high. Covers everything from basic fluid changes to complete engine and transmission rebuilds. Diagnostic Capabilities: Detailed wiring diagrams, component testing procedures, and diagnostic flowcharts for complex electronic systems. Troubleshooting Methods: Systematic troubleshooting trees based on symptoms, component resistance values, and voltage checks. ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L I4 (less common for 2005 model year in North America), 3.3L V6 OHV, 3.8L V6 OHV. Engine Code 3 3L: EGA Engine Code 3 8L: EVE, EVG Performance 3 3L V6 Horsepower: Approx. 180 hp @ 4600 RPM 3 3L V6 Torque: Approx. 205 lb-ft @ 3200 RPM 3 8L V6 Horsepower: Approx. 205 hp @ 5000 RPM 3 8L V6 Torque: Approx. 240 lb-ft @ 3400 RPM Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 20 gallons (91 octane recommended for optimal performance, especially for 3.8L) 🔧 Transmission Standard Transmission Type: 4-speed automatic transaxle Optional Transmission Options: None (4-speed automatic was standard across the board) Features Transmission Fluid Type: ATF+4 (MS-9602) Transmission Fluid Capacity: Approx. 9-10 quarts (depending on torque converter fill) 📐 Dimensions Exterior Wheelbase: Approx. 113.0 inches Length: Approx. 189.8 inches Width: Approx. 72.1 inches Height: Approx. 67.9 inches Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Size: 15-inch or 16-inch alloy or steel wheels Cargo Cargo Volume Behind 3Rd Row: Approx. 26.9 cubic feet Cargo Volume Behind 2Nd Row: Approx. 76.0 cubic feet Cargo Volume Max: Approx. 147.0 cubic feet Weights Curb Weight: Approx. 4,000-4,400 lbs (depending on configuration) Towing Capacity: Up to 3,800 lbs (with optional towing package and 3.8L engine) 🛡️ Safety Features Ratings NHTSA Front Driver Impact: 5-Star (for 2005 model year when equipped with side airbags) NHTSA Front Passenger Impact: 5-Star (for 2005 model year when equipped with side airbags) NHTSA Side Driver Impact: 4-Star (for 2005 model year) NHTSA Side Rear Passenger Impact: 4-Star (for 2005 model year) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Passive Features Airbags: Standard front driver and passenger airbags. Optional front seat-mounted side airbags. Seat Belts: 3-point seat belts for all occupants,...