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Dodge Caravan 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 2005 Vehicle Type: Minivan Codes Vehicle Platform: NS 👋 Introduction Market Position Vehicle Segment: Minivan Target Demographic: Families, individuals requiring flexible cargo and passenger space Competitive Analysis Key Competitors: Honda Odyssey, Toyota Sienna, Chevrolet Venture, Ford Windstar Key Features Vehicle Selling Points: Spacious interior, versatile seating configurations, comfortable ride, practical for families Manual Utility Primary Use Case: DIY repairs, professional diagnostics, preventative maintenance 📋 Manual Details Coverage Areas Coverage Breadth: Comprehensive Specific Models Covered: Dodge Caravan (all trim levels) Page Count Estimated Page Count: 1500+ Manual Type Manual Classification: Service and Repair Manual Content Focus: Professional automotive service and repair guidance Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L V6, 3.8L V6), Transmission (4-speed automatic) Chassis: Suspension (front and rear), Steering, Brakes (front and rear disc, ABS), Wheels and Tires Electrical: Ignition system, Charging system, Starting system, Lighting, Instrumentation, Power accessories, Body control module (BCM), Powertrain control module (PCM), Antitheft system Body And Interior: Body panels, Doors, Windows, Seats, HVAC system (heating, ventilation, air conditioning), Restraint systems (airbags, seatbelts), Trim components Procedures Included Maintenance Procedures: Oil and filter change, Air filter replacement, Spark plug replacement, Coolant flush and fill, Brake fluid flush, Transmission fluid change, Differential fluid check/change (if applicable) Repair Procedures: Engine component replacement (e.g., alternator, starter, water pump), Brake caliper/rotor replacement, Suspension component replacement (e.g., struts, ball joints), Exhaust system repair, HVAC component repair, Electrical component troubleshooting and replacement Diagnostic Procedures: Troubleshooting charts for common symptoms, OBD-II diagnostic trouble code (DTC) interpretation, Component testing procedures, Wiring diagrams for electrical systems Specifications And Tolerances: Torque specifications for critical fasteners, Fluid capacities and types, Electrical component specifications, Engine timing specifications Wiring Diagrams: Comprehensive electrical system wiring diagrams for all major circuits Technical Depth Diagnostic Complexity: Advanced diagnostics including PCM/BCM scan tool data analysis Rebuild Procedures: Detailed engine and transmission disassembly, inspection, and reassembly procedures Troubleshooting Methodology: Step-by-step troubleshooting flowcharts and diagnostic trees 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text and clear diagrams Print Capability: Printable pages for convenient workshop use Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Simulation: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type 1: 3.3L V6 SOHC (3294cc) Engine Code 1: EGA Bore X Stroke 1: 3.46 x 3.75 in (88.0 x 95.3 mm) Compression Ratio 1: 9.4:1 Horsepower 1: 180 hp @ 5000 rpm Torque 1: 205 lb-ft @ 4000 rpm Engine Type 2: 3.8L V6 OHV (3778cc) Engine Code 2: L32 Bore X Stroke 2: 3.92 x 3.37 in (99.5 x 85.5 mm) Compression Ratio 2: 9.6:1 Horsepower 2: 205 hp @ 5000 rpm Torque 2: 240 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: 87 Octane Unleaded Gasoline Fuel Tank Capacity: 20.0 gallons (75.7 L) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transaxle Transmission Code: 41TE Features Transmission Features: Electronically Controlled Overdrive, Torque Converter Lock-up Clutch Fluid Type Transmission Fluid Specification: ATF+4 (MS-9602) 📐 Dimensions Exterior Wheelbase: 119.3 inches (3030 mm) Length: 190.5 inches (4839 mm) Width: 76.7 inches (1948 mm) Height: 67.9 inches (1725 mm) Cargo Cargo Volume Behind 3Rd Row: 38.0 cubic feet (1.07 m³) Cargo Volume Behind 2Nd Row: 83.7 cubic feet (2.37 m³) Cargo Volume Behind 1St Row: 144.4 cubic feet (4.09 m³) Weights Curb Weight Min: 4260 lbs (1932 kg) Gross Vehicle Weight Rating Gvwr: 5750 lbs (2608 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (2005) NHTSA Front Impact Passenger: 4 Stars (2005) IIHS Frontal Offset Rating: Good (2005 - CRASH TESTED) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Standard front airbags for driver and passenger Seatbelts: 3-point seatbelts for all occupants, pretensioners for front seats Child Safety Anchors: LATCH (Lower Anchors and Tethers for Children) system 💡 Technology Features Infotainment Audio System Options: AM/FM stereo with CD player, optional premium audio systems, rear-seat entertainment systems Driver Assistance Cruise Control: Standard cruise control Parking Assist: Available rear parking assist sensors Connectivity Auxiliary Input: Typically not standard, may be present on aftermarket audio systems 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 7,500 miles (5,000 - 12,000 km) or 6 months, depending on oil type and driving conditions Transmission Fluid Change Interval: Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 3-4 years Coolant Flush Interval: Every 30,000 miles (48,000 km) or 2 years Spark Plug Replacement Interval 3.3L: Approx. 100,000 miles (160,000 km) with Iridium plugs Spark Plug Replacement Interval 3.8L: Approx. 100,000 miles (160,000 km) with Iridium plugs Fluid Specifications Engine Oil Specification: API Certified SAE 5W-30 (or 10W-30 if ambient temp is above 0°F/-18°C) Engine Oil Capacity 3.3L: 4.5 quarts (4.3 L) with filter Engine Oil Capacity...
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Sku: 488042
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Dodge Caravan 2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
2005
Vehicle Type:
Minivan
Codes
Vehicle Platform:
NS
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Target Demographic:
Families, individuals requiring flexible cargo and passenger space
Competitive Analysis
Key Competitors:
Honda Odyssey, Toyota Sienna, Chevrolet Venture, Ford Windstar
Key Features
Vehicle Selling Points:
Spacious interior, versatile seating configurations, comfortable ride, practical for families
Manual Utility
Primary Use Case:
DIY repairs, professional diagnostics, preventative maintenance
📋 Manual Details
Coverage Areas
Coverage Breadth:
Comprehensive
Specific Models Covered:
Dodge Caravan (all trim levels)
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Classification:
Service and Repair Manual
Content Focus:
Professional automotive service and repair guidance
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.3L V6, 3.8L V6), Transmission (4-speed automatic)
Chassis:
Suspension (front and rear), Steering, Brakes (front and rear disc, ABS), Wheels and Tires
Electrical:
Ignition system, Charging system, Starting system, Lighting, Instrumentation, Power accessories, Body control module (BCM), Powertrain control module (PCM), Antitheft system
Body And Interior:
Body panels, Doors, Windows, Seats, HVAC system (heating, ventilation, air conditioning), Restraint systems (airbags, seatbelts), Trim components
Procedures Included
Maintenance Procedures:
Oil and filter change, Air filter replacement, Spark plug replacement, Coolant flush and fill, Brake fluid flush, Transmission fluid change, Differential fluid check/change (if applicable)
Repair Procedures:
Engine component replacement (e.g., alternator, starter, water pump), Brake caliper/rotor replacement, Suspension component replacement (e.g., struts, ball joints), Exhaust system repair, HVAC component repair, Electrical component troubleshooting and replacement
Diagnostic Procedures:
Troubleshooting charts for common symptoms, OBD-II diagnostic trouble code (DTC) interpretation, Component testing procedures, Wiring diagrams for electrical systems
Specifications And Tolerances:
Torque specifications for critical fasteners, Fluid capacities and types, Electrical component specifications, Engine timing specifications
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for all major circuits
Technical Depth
Diagnostic Complexity:
Advanced diagnostics including PCM/BCM scan tool data analysis
Rebuild Procedures:
Detailed engine and transmission disassembly, inspection, and reassembly procedures
Troubleshooting Methodology:
Step-by-step troubleshooting flowcharts and diagnostic trees
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text and clear diagrams
Print Capability:
Printable pages for convenient workshop use
Binding Type
Digital Binding:
N/A (Digital PDF)
Paper Type
Digital Paper Simulation:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
3.3L V6 SOHC (3294cc)
Engine Code 1:
EGA
Bore X Stroke 1:
3.46 x 3.75 in (88.0 x 95.3 mm)
Compression Ratio 1:
9.4:1
Horsepower 1:
180 hp @ 5000 rpm
Torque 1:
205 lb-ft @ 4000 rpm
Engine Type 2:
3.8L V6 OHV (3778cc)
Engine Code 2:
L32
Bore X Stroke 2:
3.92 x 3.37 in (99.5 x 85.5 mm)
Compression Ratio 2:
9.6:1
Horsepower 2:
205 hp @ 5000 rpm
Torque 2:
240 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
87 Octane Unleaded Gasoline
Fuel Tank Capacity:
20.0 gallons (75.7 L)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transaxle
Transmission Code:
41TE
Features
Transmission Features:
Electronically Controlled Overdrive, Torque Converter Lock-up Clutch
Fluid Type
Transmission Fluid Specification:
ATF+4 (MS-9602)
📐 Dimensions
Exterior
Wheelbase:
119.3 inches (3030 mm)
Length:
190.5 inches (4839 mm)
Width:
76.7 inches (1948 mm)
Height:
67.9 inches (1725 mm)
Cargo
Cargo Volume Behind 3Rd Row:
38.0 cubic feet (1.07 m³)
Cargo Volume Behind 2Nd Row:
83.7 cubic feet (2.37 m³)
Cargo Volume Behind 1St Row:
144.4 cubic feet (4.09 m³)
Weights
Curb Weight Min:
4260 lbs (1932 kg)
Gross Vehicle Weight Rating Gvwr:
5750 lbs (2608 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (2005)
NHTSA Front Impact Passenger:
4 Stars (2005)
IIHS Frontal Offset Rating:
Good (2005 - CRASH TESTED)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Standard front airbags for driver and passenger
Seatbelts:
3-point seatbelts for all occupants, pretensioners for front seats
Child Safety Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with CD player, optional premium audio systems, rear-seat entertainment systems
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Available rear parking assist sensors
Connectivity
Auxiliary Input:
Typically not standard, may be present on aftermarket audio systems
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 7,500 miles (5,000 - 12,000 km) or 6 months, depending on oil type and driving conditions
Transmission Fluid Change Interval:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 3-4 years
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 2 years
Spark Plug Replacement Interval 3.3L:
Approx. 100,000 miles (160,000 km) with Iridium plugs
Spark Plug Replacement Interval 3.8L:
Approx. 100,000 miles (160,000 km) with Iridium plugs
Fluid Specifications
Engine Oil Specification:
API Certified SAE 5W-30 (or 10W-30 if ambient temp is above 0°F/-18°C)
Engine Oil Capacity 3.3L:
4.5 quarts (4.3 L) with filter
Engine Oil Capacity 3.8L:
5.0 quarts (4.7 L) with filter
Coolant Specification:
Chrysler OAT (Organic Acid Technology) or HOAT (Hybrid OAT) Antifreeze/Coolant - Mopar or equivalent
Brake Fluid Specification:
DOT 3
Known Issues
Common Complaints:
Transmission issues (solenoids, torque converter), EGR valve problems, Suspension wear (ball joints, struts), Oil leaks (valve covers, oil pan), Power sliding door malfunctions
Recall Information:
Consult NHTSA or dealer for specific recalls related to the 2005 Dodge Caravan.
📚 Vehicle History
Brand Heritage
Dodge Heritage:
Dodge, a division of Chrysler, has a long history in the automotive industry, known for performance and practical vehicles.
Model Evolution
Caravan Generation:
Third Generation (NS) - 1996-2000, Facelifted for 2001-2007
2005 Model Updates:
Minor styling updates, potential feature additions across trim levels.
Production
Production Location:
Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Car And Driver Best Bet:
Caravan often cited for value and practicality in its segment during its production years.
Ratings
Consumer Reports Reliability:
Varies by year and specific components; 2005 may exhibit average to below-average reliability in certain areas, particularly transmission.
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