2005 Caravan Grand Caravan by Dodge Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Grand Voyager Production Year: 2005 Associated Brands: Chrysler Codes Platform Code: RS/RG 👋 Introduction Market Position Vehicle Segment: Minivan Target Audience: Families, individuals needing versatile cargo and passenger transport. Competitive Analysis Key Competitors 2005: Honda Odyssey, Toyota Sienna, Ford Freestar, Chevrolet Venture. Key Features Manual Value Proposition: Checked and reorganized PDF for usability, working links, comprehensive coverage, and manufacturer-written content. Vehicle Strengths General: Spacious interior, flexible seating, powerful engine options, comfortable ride for its class. Manual Quality Manual Endorsement: Written by the Manufacturer, Used by Dealership Mechanics. 📋 Manual Details Coverage Areas Regions Covered: USA and Europe Page Count Page Count: Unknown (Specific page count not provided in product information, but described as 'Most Complete Workshop Manual Available') Manual Type Manual Type: Service Repair Manual / Workshop Manual Origin Of Manual: Original RS RG Service Shop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: 2.4L DOHC, 2.5L Turbo Diesel, 2.8L Turbo Diesel, 3.3L V-6, 3.8L V-6 Transmission Systems: Automatic Transaxle 41-TE, Manual Transaxle T-850 Chassis Systems: Suspension, Differential & Driveline, Brakes, Frame & Bumpers, Steering, Tires/Wheels Body Systems: Body, Heating & Air Conditioning, Exhaust System Electrical Systems: Audio, Chime/Buzzer, Electronic Control Modules, Engine Systems, Heated Systems, Horn, Ignition Control, Instrument Cluster, Lamps, Message Systems, Power Systems, Restraints, Speed Control, Vehicle Theft Security, Wipers/Washers, Wiring Emissions Systems: Emissions Control (specifically for 2.5L Turbo Diesel mentioned) Specific Engine Coverage: 2.5L Turbo Diesel cooling and emissions systems are specifically detailed. Component Index: Includes a Component and System Index for quick reference. Procedures Included Maintenance Procedures: Lubrication, Maintenance Schedules Diagnostic Procedures: Technical Diagnostic Procedures Repair Procedures: Disassembly & Installation Procedures Wiring Information: Wiring Diagrams Disassembly Assembly: Detailed Disassembly & Installation Procedures for components and systems. Technical Depth Depth Of Coverage: Comprehensive Workshop Manual covering all aspects from basic maintenance to advanced diagnostics and repair. Visual Aids: Numerous Illustrations & Diagrams 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable PDF Bookmarking: Fully Bookmarked PDF Link Integrity: All links in every page work correctly and navigate to the proper page. File Organization: Each file is checked and reorganized to be a very useful PDF. Print Quality Print Capability: Printable pages (specific or whole manual) Binding Type Binding Type: Digital (PDF format) Paper Type Paper Type: N/A (Digital format) Software Compatibility Operating Systems: Windows XP, Vista, 7, 8, and Mac ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.4L Engine 1 Configuration: DOHC (Dual Overhead Camshafts) Engine 2 Displacement: 2.5L Engine 2 Type: Turbo Diesel Engine 3 Displacement: 2.8L Engine 3 Type: Turbo Diesel Engine 4 Displacement: 3.3L Engine 4 Configuration: 60° V-6 Engine 5 Displacement: 3.8L Engine 5 Configuration: 60° V-6 Performance Horsepower 3.3L V6: Approx. 180-185 hp (typical for this period, specific figures may vary) Torque 3.3L V6: Approx. 205-210 lb-ft (typical for this period) Horsepower 3.8L V6: Approx. 205-215 hp (typical for this period) Torque 3.8L V6: Approx. 235-245 lb-ft (typical for this period) Fuel System Fuel Delivery Gasoline: Multi-Port Fuel Injection (MPI) Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Standard Transmission: 4-Speed Automatic Transaxle (41-TE) Optional Optional Transmission: 5-Speed Manual Transaxle (T-850, likely for specific configurations or markets) Features Automatic Transmission Features: Electronically controlled, adaptive shifting logic. 📐 Dimensions Exterior Wheelbase Rs: Approx. 113.3 inches (for standard wheelbase Caravan/Voyager) Wheelbase Rg: Approx. 119.3 inches (for long wheelbase Grand Caravan/Grand Voyager/Town & Country) Weights Curb Weight Typical: Approx. 4,000 - 4,500 lbs (varies by engine and configuration) Cargo Cargo Volume Behind 3Rd Row: Approx. 30-40 cubic feet (varies by configuration) Cargo Volume Max: Approx. 140-160 cubic feet (with seats removed, varies by configuration) 🛡️ Safety Features Ratings NHTSA Frontal Crash Driver: Likely 4-star or 5-star (based on common ratings for this generation, specific testing may vary) NHTSA Frontal Crash Passenger: Likely 4-star or 5-star IIHS Frontal Offset: Likely 'Good' or 'Acceptable' (specific ratings vary by year/testing) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional or standard on higher trims/engines Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front and rear side curtain airbags available Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system 💡 Technology Features Infotainment Infotainment Options: Available AM/FM stereo with CD player, optional satellite radio, available rear-seat entertainment system. Driver Assistance Cruise Control: Standard or available Speed Control Connectivity Keyless Entry: Available keyless entry system 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-7,500 miles or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations). Transmission Fluid Change Interval: Generally recommended every 30,000-100,000 miles, with regular checks for level and condition (manual specific). Fluid Specifications Engine Oil Specification: API certified engine oil, viscosity grade typically 5W-20 or 5W-30 for gasoline engines (refer to manual for exact spec). Transmission Fluid...
Approx. 113.3 inches (for standard wheelbase Caravan/Voyager)
Wheelbase Rg:
Approx. 119.3 inches (for long wheelbase Grand Caravan/Grand Voyager/Town & Country)
Weights
Curb Weight Typical:
Approx. 4,000 - 4,500 lbs (varies by engine and configuration)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 30-40 cubic feet (varies by configuration)
Cargo Volume Max:
Approx. 140-160 cubic feet (with seats removed, varies by configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Driver:
Likely 4-star or 5-star (based on common ratings for this generation, specific testing may vary)
NHTSA Frontal Crash Passenger:
Likely 4-star or 5-star
IIHS Frontal Offset:
Likely 'Good' or 'Acceptable' (specific ratings vary by year/testing)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional or standard on higher trims/engines
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front and rear side curtain airbags available
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Infotainment Options:
Available AM/FM stereo with CD player, optional satellite radio, available rear-seat entertainment system.
Driver Assistance
Cruise Control:
Standard or available Speed Control
Connectivity
Keyless Entry:
Available keyless entry system
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Transmission Fluid Change Interval:
Generally recommended every 30,000-100,000 miles, with regular checks for level and condition (manual specific).
Fluid Specifications
Engine Oil Specification:
API certified engine oil, viscosity grade typically 5W-20 or 5W-30 for gasoline engines (refer to manual for exact spec).
Transmission Fluid Specification 41Te:
Chrysler ATF+4 (or equivalent specification)
Coolant Specification:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology) or equivalent
Known Issues
Common Engine Issues:
Oil leaks (valve cover gaskets, oil pan gaskets), potential intake manifold gasket leaks, spark plug issues (e.g., broken spark plugs in 2.7L V6, though not listed in this manual's engines, it's a common Dodge issue of the era), sometimes cooling system leaks.
Common Transmission Issues:
Wear on internal clutch packs and seals in the 41TE automatic transmission, potential issues with solenoids.
Common Electrical Issues:
Power window failures, interior lighting issues, intermittent sensor faults.
Common Suspension Issues:
Wear in ball joints, tie rod ends, and control arm bushings leading to noise and steering wander.
📚 Vehicle History
Brand Heritage
Dodge Heritage Vans:
Dodge has a long history with the minivan segment, pioneering many features and maintaining a strong market presence since the original Caravan's introduction.
Model Evolution
Minivan Generation:
This manual covers the fourth generation (2001-2007) of the Dodge Caravan/Grand Caravan platform.