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GROUP TAB LOCATOR Introduction

0 2 3 5 7 8A 8B 8E 8F 8G 8H 8I 8J 8L 8M 8N 8O 8P 8Q 8R 8T 8W 9 11 13 14 19 21 22 23 24 25

Lubrication & Maintenance Suspension Differential & Driveline Brakes Cooling 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 Navigation/Telecommunication Wiring Engine Exhaust System Frame & Bumpers Fuel System Steering Transmission/Transaxle Tires/Wheels Body Heating & Air Conditioning Emissions Control Component and System Index

Service Manual Comment Forms

(Rear of Manual)


INTRODUCTION

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INTRODUCTION TABLE OF CONTENTS page BODY CODE PLATE DESCRIPTION . . . . . . . . . . FASTENER IDENTIFICATION DESCRIPTION . . . . . . . . . . FASTENER USAGE DESCRIPTION FASTENER USAGE . . . . . THREADED HOLE REPAIR INTERNATIONAL SYMBOLS DESCRIPTION . . . . . . . . . . METRIC SYSTEM DESCRIPTION . . . . . . . . . .

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page TORQUE REFERENCES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 VEHICLE IDENTIFICATION NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VEHICLE CERTIFICATION LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 E-MARK LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 VECI LABEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 MANUFACTURER PLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11

BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 1) is located in the engine compartment on the radiator closure panel crossmember. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate.

BODY CODE PLATE – LINE 3 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13 THROUGH 17 Open Space DIGITS 18 AND 19 Vehicle Shell Line • RS DIGIT 20 Carline

FWD • K = Dodge • Y = Chrysler

Fig. 1 BODY CODE PLATE 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - VINYL ROOF 4 - VEHICLE ORDER NUMBER 5 - CAR LINE SHELL 6 - PAINT PROCEDURE 7 - ENGINE 8 - TRIM 9 - TRANSMISSION 10 - MARKET 11 - VIN

AWD • C = Chrysler • D = Dodge


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BODY CODE PLATE (Continued) DIGIT 21 Price Class • H = Highline • L = Lowline • P = Premium • S = Luxury • X = Premium

BODY CODE PLATE LINE 1

DIGITS 22 AND 23 Body Type • 52 = Short Wheel Base • 53 = Long Wheel Base

DIGIT 4 Open Space

DIGITS 1, 2, AND 3 Transaxle Codes • DGC = 31TH 3-Speed Automatic Transaxle • DGL = 41AE/TE 4-Speed Electronic Automatic • DDR = T850 5-Speed Manual Transaxle

DIGITS 1, 2 AND 3 Paint Procedure

DIGIT 5 Market Code • C = Canada • B = International • M = Mexico • U = United States

DIGIT 4 Open Space

DIGIT 6 Open Space

DIGITS 5 THROUGH 7 Primary Paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS).

DIGITS 7 THROUGH 23 Vehicle Identification Number • Refer to Vehicle Identification Number (VIN) paragraph for proper breakdown of VIN code.

BODY CODE PLATE LINE 2

DIGIT 8 AND 9 Open Space

IF TWO BODY CODE PLATES ARE REQUIRED

DIGIT 13 AND 14 Open Space

The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will indicate (CTD) When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates.

DIGITS 15 THROUGH 18 Interior Trim Code

FASTENER IDENTIFICATION

DIGITS 10 THROUGH 12 Secondary Paint

DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline (MPI) • EGA = 3.3L 6 cyl. Gasoline (SMPI) • EGH = 3.8L 6 cyl. Gasoline (SMPI) • EGM = 3.3L 6 cyl. Ethanol Flexible Fuel • ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel DIGIT 23 Open Space

DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts.


INTRODUCTION

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FASTENER IDENTIFICATION

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FASTENER IDENTIFICATION (Continued)

FASTENER STRENGTH


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FASTENER USAGE

THREADED HOLE REPAIR

DESCRIPTION

Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommendations for application and repair procedures.

FASTENER USAGE

INTERNATIONAL SYMBOLS

WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PERSONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 2 3 4 5 6 7 8 9 10 11 12

High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Wind screen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper

13 14 15 16 17 18 19 20 21 22 23 24

Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter


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The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY

BY

TO GET

MULTIPLY

BY

TO GET

in-lbs

x 0.11298

= Newton Meters (N·m)

N·m

x 8.851

= in-lbs

ft-lbs

x 1.3558

= Newton Meters (N·m)

N·m

x 0.7376

= ft-lbs

Inches Hg (60° F)

x 3.377

= Kilopascals (kPa)

kPa

x 0.2961

= Inches Hg

psi

x 6.895

= Kilopascals (kPa)

kPa

x 0.145

= psi

Inches

x 25.4

= Millimeters (mm)

mm

x 0.03937

= Inches

Feet

x 0.3048

= Meters (M)

M

x 3.281

= Feet

Yards

x 0.9144

= Meters

M

x 1.0936

= Yards

mph

x 1.6093

= Kilometers/Hr. (Km/h)

Km/h

x 0.6214

= mph

Feet/Sec

x 0.3048

= Meters/Sec (M/S)

M/S

x 3.281

= Feet/Sec

mph

x 0.4470

= Meters/Sec (M/S)

M/S

x 2.237

= mph

Kilometers/Hr. (Km/h)

x 0.27778

= Meters/Sec (M/S)

M/S

x 3.600

Kilometers/Hr. (Km/h)

COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters

1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter

1 Cubic Foot = 0.03 Cubic Meter

1 Yard = 0.9 Meter

1 Cubic Yard = 0.8 Cubic Meter

1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.).


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INTRODUCTION

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METRIC CONVERSION CHART

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TORQUE REFERENCES DESCRIPTION

TORQUE SPECIFICATIONS


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TORQUE REFERENCES (Continued) Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts.

tion. The formula to use the check digit is not released to the general public.

VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number (VIN) can be viewed through the windshield at the upper left corner of the instrument panel, near the left windshield pillar (Fig. 2). The VIN consists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle. Refer to VIN Code Breakdown Chart for decoding information. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the vehicle identification number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta-

Fig. 2 VEHICLE IDENTIFICATION NUMBER (VIN) 1 - DEFROSTER OUTLET 2 - VEHICLE IDENTIFICATION NUMBER 3 - HEATED WINDSHIELD GRID

VIN CODE BREAKDOWN CHART POSITION

INTERPRETATION Country of Origin

CODE = DESCRIPTION 1 = Manufactured By DaimlerChrysler Corporation

1 2 = Manufactured By DaimlerChrysler Canada Inc. 2

Make

D = Dodge C = Chrysler

Vehicle Type

4 = Multipurpose Pass. Vehicle Less Side Air Bags

3 8 = Multipurpose Pass. Vehicle With Side Air Bags 4

Gross Vehicle Weight Rating

G = 2268 - 2721 kg. (5001 - 6000 lbs.) 1 = Chrysler Caravan - FWD P = Chrysler, Town & Country - FWD P = Dodge, Caravan/Grand Caravan - FWD P = Dodge, Caravan C/V, Grand Caravan C/V - FWD T = Chrysler, Town & Country - AWD

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Car Line

T = Dodge, Grand Caravan - AWD J = Chrysler, Voyager/Grand Voyager - FWD Y = Voyager/Grand Voyager - FWD Left Hand Drive C = Voyager/Grand Voyager - AWD Left Hand Drive H = Voyager/Grand Voyager - FWD Right Hand Drive K = Voyager/Grand Voyager - AWD Left Hand Drive


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VEHICLE IDENTIFICATION NUMBER (Continued) POSITION

INTERPRETATION

CODE = DESCRIPTION 2 = Low Line 3 = Medium

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Series

4 = High Line 5 = Premium 6 = Sport 7 = Special

6 - Export

Series

B = 4-Speed Automatic Transaxle N = 5-Speed Manual Transaxle 1 = Van - Caravan C/V

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Body Style

3 = Extended Van - Grand Caravan C/V 4 = Extended Wagon - Grand Caravan/Town & Country 5 = Wagon - Caravan, Voyager, Town & Country 1 = EURO Wagon - Long Wheelbase (RG - 53 - S Series) 2 = EURO Wagon - Short Wheelbase (RG - 52 - H Series) 3 = EURO Wagon - Short Wheelbase (RG - 52 - P Series) 4 = EURO Wagon - Long Wheelbase (RG - 53 - P Series) 5 = EURO Wagon - Long Wheelbase (RG - 53 - H Series)

7 - Export

Body Style

6 = Commercial Van - Short Wheelbase (with- Sales Code CYX Less AS8) 7 = Commercial Van - Short Wheelbase (with Sales Code AS8) 8 = Commercial Van-Long Wheelbase (H - Series with Sales Code - CYX) 9 = Commercial Van - Long Wheelbase (P - Series with Sales Code - CYX) B = 2.4L I4 Cyl. 16-Valve Gasoline DOHC (MPI) E = 3.3L V6 Cyl. OHV Flex Fuel

8

Engine

L = 3.8L V6 Cyl. Gasoline (SMPI) R = 3.3L V6 Cyl. OHV Gasoline 5 = 2.8L I4 Cyl. Turbo Diesel 7 = 2.5L I4 Cyl. 16 Valve Turbo Diesel

9

Check Digit

See explanation in this section.

10

Model Year

5 = 2005

11

Assembly Plant

B = St. Louis Assembly South R = Windsor Assembly U = Eurostar Gesellschaftz Assembly

12 through 17

Sequence Number

A six digit number assigned by assembly plant.


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VEHICLE CERTIFICATION LABEL DESCRIPTION A vehicle certification label is attached to the rear shutface of the driver’s door (Fig. 3). This label indicates date of manufacture (month and year), Gross Vehicle Weight Rating (GVWR), Gross Axle Weight Rating (GAWR) front, Gross Axle Weight Rating (GAWR) rear and the Vehicle Identification Number (VIN). The Month, Day and Hour of manufacture is also included. All communications or inquiries regarding the vehicle should include the Month-Day-Hour and Vehicle Identification Number.

Fig. 4 E-MARK LABEL 1 2 3 4

- COUNTRY CODE - REGULATION NUMBER - APPROVAL NUMBER - AMENDMENT NUMBER

VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Information (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label.

Fig. 3 VEHICLE CERTIFICATION LABEL - TYPICAL

E-MARK LABEL

MANUFACTURER PLATE

DESCRIPTION

DESCRIPTION

An E-mark Label (Fig. 4) is located on the rear shut face of the driver’s door. The label contains the following information: • Date of Manufacture • Month-Day-Hour (MDH) • Vehicle Identification Number (VIN) • Country Codes • Regulation Number • Regulation Amendment Number • Approval Number

The Manufacturer Plate (Fig. 5) is located in the engine compartment on the passenger side rear corner of the hood. The plate contains five lines of information: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3. Gross Train Mass (GTM) 4. Gross Front Axle Rating (GFAR) 5. Gross Rear Axle Rating (GRAR)

Fig. 5 MANUFACTURER PLATE

Profile for 16391012

2005 DODGE CARAVAN Service Repair Manual  

2005 DODGE CARAVAN Service Repair Manual  

Profile for 16391012
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