2005 Dodge Grand Caravan Service and Repair Manual

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Factory-Grade Data

2005 Dodge Grand Caravan service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • SE Plus Mini Passenger Van 4-Door
  • SE Mini Passenger Van 4-Door
  • C/V Mini Cargo Van 3-Door
  • Base Mini Passenger Van 4-Door
  • SXT Mini Passenger Van 4-Door

Engines covered

  • 3.3L 3301CC 201Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.3L 3301CC 201Cu. In. V6 FLEX OHV Naturally Aspirated
  • 3.8L 3778CC 231Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

Payment & Security

Payment methods

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  • Bancontact
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  • Mastercard
  • PayPal
  • Union Pay
  • Visa

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Vehicle Safety Data

2005 Dodge Grand Caravan Recalls & Complaints

NHTSA #10V27100015/06/2010Component: EQUIPMENT ADAPTIVE/MOBILITY

ALL IN ONE MOBILITY IS RECALLING CERTAIN MODEL YEAR 1997 THROUGH 2008 CONVERSION VANS EQUIPPED WITH VMI/RICON 6-WAY POWER SEAT BASES. THERE IS A POSSIBILITY OF A DEFECTIVE WELD AT THE JOINT BETWEEN T

Consequence

THE SEAT OCCUPANT MAY BE INJURED IF THE SEAT BASE PIN WERE TO BREAK.

Remedy

ALL IN ONE MOBILITY WILL NOTIFY OWNERS AND THE VEHICLES WILL BE REPAIRED FREE OF CHARGE. THE SAFETY

NHTSA #10V26100014/06/2010Component: SEATS

ARIZONA MOBILITY PRODUCTS (AMP) IS RECALLING ONE 2005 AND ONE 2007 CONVERSION VANS BUILT ON DODGE GRAND CARAVAN CHASSIS EQUIPPED WITH VMI/RICON 6-WAY POWER SEAT BASES. THERE IS A POSSIBILITY OF A DEF

Consequence

THE SEAT OCCUPANT MAY BE INJURED IF THE SEAT BASE PIN WERE TO BREAK.

Remedy

AMP WILL NOTIFY OWNERS AND REPAIR VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 10, 2010

NHTSA #10V00800011/01/2010Component: AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2005-2006 DODGE CARAVAN, GRAND CARAVAN AND CHRYSLER TOWN & COUNTRY VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE,

Consequence

IF THE FRONT CRASH SENSORS BECOME INOPERATIVE, THE DRIVER IS IMMEDIATELY ALERTED BY ILLUMINATION OF

Remedy

CHRYSLER WILL REPLACE THE FRONT AIRBAG SENSORS WITH A NEW DESIGN. THIS SERVICE WILL BE PERFORMED FRE

NHTSA #06V06700008/03/2006Component: VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

ON CERTAIN VANS AND SPORT UTILITY VEHICLES, THE FRONT WINDSHIELD WIPER MOTOR ARMATURE SHAFT MAY BREAK.

Consequence

DURING CERTAIN OPERATING CONDITIONS, LOSS OF FRONT WINDSHIELD WIPING CAPABILITY COULD OCCUR, AND THE

Remedy

DEALERS WILL INSPECT AND REPLACE THE WINDSHIELD WIPER MOTOR FREE OF CHARGE. THE RECALL BEGAN ON JU

NHTSA #04V04700003/02/2004Component: SEAT BELTS:FRONT:RETRACTOR

AFTER PERFORMING THE NCAP TEST, IT WAS DISCOVERED THAT ON CERTAIN MINIVANS EQUIPPED WITHOUT THE AVAILABLE "STOW 'N GO" SEATING OPTION, THE RIGHT FRONT SEAT BELT RETRACTOR ASSEMBLY MAY HAVE BEEN IMPROP

Consequence

AS A RESULT, THE SEAT BELT MAY NOT PROPERLY RESTRAIN THE OCCUPANT DURING CERTAIN CRASH CONDITIONS, W

Remedy

DEALERS WILL INSPECT THE RETRACTOR ASSEMBLIES AND ANY SEAT BELT ASSEMBLY THAT DOES NOT HAVE THE STAK

TSB #10229256

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10221686

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10221097

Transmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles. If the transmission bracket to the transmission case fasteners are removed during servicing, the fasteners (Part Number 06511385A$) are one-time usage

TSB #10220840

Transmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles. If the transmission bracket to the transmission case fasteners are removed during servicing, the fasteners (Part Number 06511385A$) are one-time usage

TSB #10219763

Extended Warranty on the Fuel Tank/Vapor Cannister

TSB #10209634

Extended Warranty on the Fuel Tank/Vapor Cannister

TSB #10191460

Valve Body. These may cause over drive cycling.

TSB #10175735

Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are neces

Showing the 8 most recent of 32 technical service bulletins on file with NHTSA.

20070908Component: ELECTRICAL SYSTEMCrash reportedFire reported

VEHICLE--DODGE GRAND CARAVAN (2005)- WAS TRAVELING ABOUT 30 MILES AN HOUR AND RIGHT FRONT FENDER/LIGHT AREA STRUCK CONCRETE BARRIER. IMMEDIATELY UPON IMPACT, SPARKS CAME SHOOTING OUT, TIRE CAUGHT ON

20061130Component: AIR BAGS:FRONTALCrash reported5 injured

DT*: THE CONTACT STATED WHILE TRAVELING 50 MPH, THE VEHICLE WAS INVOLVED IN A HEAD ON COLLISION, AND THE AIRBAGS DID NOT DEPLOY. 5 OCCUPANTS SUSTAINED INJURIES, AND A POLICE REPORT WAS TAKEN. THE AI

20070216Component: AIR BAGS:FRONTALCrash reported4 injured

TL*- THE CONTACT STATED THAT WHILE DRIVING THE 2005 DODGE GRAND CARAVAN A VEHICLE HIT THE CONTACT'S VEHICLE FROM BEHIND. THE CONTACT WAS SITTING AT A RAILROAD STOP WAITING FOR A TRAIN TO PASS WHEN

20070216Component: SEAT BELTS:FRONT:RETRACTORCrash reported4 injured

TL*- THE CONTACT STATED THAT WHILE DRIVING THE 2005 DODGE GRAND CARAVAN A VEHICLE HIT THE CONTACT'S VEHICLE FROM BEHIND. THE CONTACT WAS SITTING AT A RAILROAD STOP WAITING FOR A TRAIN TO PASS WHEN

20111114Component: AIR BAGSCrash reported3 injured

I WAS INVOLVED IN A MAJOR FRONT END HEAD ON COLLISION AND MY AIRBAGS FAILED TO DEPLOY. MY HUSBAND WAS A PASSENGER AND HIT THE WINDSHIELD. I WAS TOLD BY THE GARAGE WHERE IT WAS TOWED TO THAT IF MY AIRB

Showing the 5 most serious of 1341 complaints filed with NHTSA.

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