🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Product Name:

DODGE CARAVAN Factory Service Repair Manual

Product Description:

OFFICIAL FACTORY SERVICE REPAIR WORKSHOP MANUAL FOR US/CANADA MODEL

👋 Introduction

Market Segment:

Minivan, Family Vehicle

Positioning Statement:

The Dodge Caravan has historically been a cornerstone in the minivan segment, known for its practicality, versatility, and affordability, making it a popular choice for families.

Key Competitors:

Toyota Sienna, Honda Odyssey, Chrysler Town & Country/Voyager, Ford Windstar/Freestar.

Defining Features:

Stow 'n Go seating (on later models), ample interior space, front-wheel drive, comfortable ride, and a wide range of powertrain options over its production life.

📋 Manual Details

Regions Covered:

United States and Canada

Estimated Page Count:

Extensive (Specific count not provided, but factory service manuals are typically hundreds to over a thousand pages)

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Powertrain:

Engine mechanical, engine control systems, fuel system, exhaust system, transmission (automatic/manual), drivetrain components (FWD).

Chassis:

Suspension system (front and rear), steering system, brake system (ABS, EBD, Traction Control), wheel and tire specifications.

Electrical:

Battery, charging system, starting system, lighting, instrument cluster, body control module (BCM), power windows, locks, mirrors, HVAC controls, audio systems, safety systems (airbags, seatbelts).

Body:

Body and frame construction, exterior trim, interior trim, doors, glass, seats, HVAC system operation and repair.

Maintenance:

Scheduled maintenance intervals, fluid checks and changes, filter replacements, lubrication points.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), diagnostic procedures for all major systems, wiring diagrams.

Repair:

Step-by-step repair procedures for all major components and systems, disassembly and reassembly instructions, specifications for torque, alignment, and adjustments.

Special Tools:

Identification and usage of specialized tools required for specific repairs and diagnostics.

Engine Rebuild:

Detailed procedures for engine disassembly, inspection, component replacement, and reassembly, including torque specifications and clearances.

Transmission Overhaul:

Comprehensive instructions for automatic transmission disassembly, repair of internal components (clutches, bands, valve body), and reassembly.

Electrical Troubleshooting:

In-depth electrical troubleshooting flowcharts, component testing procedures, and complete wiring diagrams for all vehicle systems.

Body Repair:

Guidelines for body panel alignment, rust repair, and interior component removal/installation.

Depth:

Comprehensive, covering everything from basic fluid checks to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic strategies.

Diagnostic Tools Required:

Standard OBD-II scanner for engine diagnostics. Chrysler-specific diagnostic tools (e.g., StarSCAN, wiTECH) may be required for advanced module programming and component testing. The manual will detail necessary diagnostic procedures.

📊 Manual Specifications

File Format Details:

PDF - searchable, zoomable, and printable. Compatible with a wide range of operating systems and devices.

Print Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding Type:

Digital (PDF - No physical binding)

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Engine Options Typical:

Varies by generation and model year. Common engines include: 2.4L I4, 3.0L V6, 3.3L V6, 3.8L V6, 4.0L V6.

Horsepower Range Typical:

Approximately 150 HP to 250 HP depending on engine and model year.

Torque Range Typical:

Approximately 170 lb-ft to 260 lb-ft depending on engine and model year.

Fuel Delivery:

Multi-port fuel injection (MPI) is common across most V6 engines; some earlier or base models might have used Throttle Body Injection (TBI) or Carburetion.

Fuel Type:

Unleaded Gasoline

Coolant Type:

Chrysler's HOAT (Hybrid Organic Acid Technology) antifreeze or equivalent. Refer to manual for specific color and specification (e.g., 5-year/100,000 mile pink coolant).

Oil Type Typical:

SAE 5W-30 or 5W-40, API Certified. Always consult the manual for the precise specification based on engine and climate.

Common Engine Codes:

Examples: EGW (3.0L V6), EHD (3.3L V6), GWA (3.8L V6), NAG (4.0L V6). Specific codes are generation and year dependent.

🔧 Transmission

Transmission Type Standard:

Automatic Transmission (most common)

Transmission Type Optional:

Some early models may have offered manual transmissions, but these are exceedingly rare.

Transmission Variants:

Commonly the 3-speed Torqueflite (A604, A670) and 4-speed Ultradrive (A606, 42LE) automatic transmissions were used.

Transmission Fluid Type:

Chrysler ATF+4 (or equivalent specification like Mopar ATF+4). Earlier transmissions may have used ATF+2 or ATF+3. Consult the manual for specific fluid requirements based on transmission model and year.

📐 Dimensions

Overall Length Typical:

Varies by generation, but generally around 175-190 inches for shorter wheelbase and 200-215 inches for extended wheelbase (Grand Caravan).

Overall Width Typical:

Around 70-75 inches.

Overall Height Typical:

Around 65-69 inches.

Max Cargo Volume Typical:

Often exceeding 100 cubic feet, with some models reaching up to 160+ cubic feet with second and third-row seats stowed or removed.

Curb Weight Typical:

Approximately 3,500 - 4,500 lbs, depending on engine, drivetrain, and features.

Towing Capacity Typical:

Typically rated up to 2,000 - 3,800 lbs, often requiring a factory-installed towing package.

🛡️ Safety Features

NHTSA Ratings Typical:

Varies significantly by model year and specific test. Earlier models may have lower ratings compared to later generations with enhanced safety features. Refer to NHTSA for specific year data.

Active Safety Features:

Anti-lock Braking System (ABS), Traction Control System (TCS), Electronic Stability Control (ESC) on later models.

Passive Safety Features:

Driver and front passenger airbags, side curtain airbags (on later models), three-point seatbelts for all occupants, LATCH child seat anchors.

Common Recall Areas:

Potential recalls have historically involved airbag systems, fuel system components, and power sliding door mechanisms, depending on the model year.

💡 Technology Features

Infotainment Systems Typical:

Early models featured basic AM/FM radios with cassette/CD players. Later models offered touchscreen infotainment systems with navigation, Bluetooth, rear-seat entertainment systems, and satellite radio.

Driver Assistance Features:

Rear parking sensors, rearview cameras (on later models), cruise control.

Connectivity Options:

Bluetooth for hands-free calling and audio streaming, USB ports for device charging and media playback (on later models).

Comfort Features Typical:

Power sliding doors, power liftgate, tri-zone automatic climate control, heated seats, power adjustable pedals.

🔧 Maintenance

Oil Change Interval Typical:

Every 3,000-5,000 miles for conventional oil, or 7,500-10,000 miles for synthetic oil. Consult the manual for specific recommendations based on driving conditions and oil type.

Tire Rotation Interval:

Every 5,000 - 7,500 miles.

Cabin Air Filter Replacement:

Typically every 12,000 - 15,000 miles or annually, depending on conditions.

Spark Plug Replacement:

Varies by engine type (e.g., platinum/iridium plugs can last 100,000+ miles, while conventional plugs may need replacement around 30,000-60,000 miles).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid, as specified in the manual. Chrysler recommends Pentastar DOT 4 or equivalent.

Power Steering Fluid Type:

Chrysler power steering fluid or equivalent specification. Consult the manual for the correct type.

Coolant Capacity Typical:

Approximately 12-14 quarts (11.4-13.2 liters), depending on engine size. Verify with the manual.

Common Wear Items:

CV axles, ball joints, tie rod ends, brake pads/rotors, wheel bearings, transmission solenoids/clutches (especially on earlier models).

Typical Electrical Problems:

Intermittent power window/lock issues, HVAC blower motor failures, dashboard warning lights, PCM (Powertrain Control Module) issues.

Engine Related Issues:

Oil leaks from valve cover gaskets or oil pan, intake manifold gasket failures (on some V6 engines), EGR valve issues.

Transmission Behavior:

Hesitation, slipping, or harsh shifting can indicate issues with transmission fluid, solenoids, or internal wear.

📚 Vehicle History

Dodge Brand Legacy:

Dodge, a division of Chrysler (now Stellantis), has a long history of producing practical and performance-oriented vehicles, with the Caravan being a significant contributor to its utility segment.

First Generation:

Introduced in 1984, pioneering the modern minivan segment alongside its Chrysler sibling.

Key Generations And Features:

Generations saw significant updates including AWD options, longer wheelbases (Grand Caravan), Stow 'n Go seating, and advanced powertrain technologies.

Production Period:

Produced from 1984 to 2020 (with a brief hiatus and discontinuation in North America after the 2019 model year for the Dodge brand itself, though Chrysler Voyager/Pacificas continued).

Manufacturing Locations:

Primarily manufactured in Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

🏆 Awards & Recognition

Major Awards Or Recognitions:

The Caravan has frequently been recognized for its value and utility, often appearing on 'best family vehicle' lists and achieving positive ratings from automotive journalists and consumer organizations over its decades of production.