🏷️ Basic Information

Make:

Dodge, Chrysler, Plymouth

Model:

Caravan, Town & Country, Voyager

Year Range:

1992-1996

Platform Code:

ASG (Autostick Gearbox), NS (North American Segment)

👋 Introduction

Vehicle Segment:

Minivan

Key Competitors:

Ford Aerostar, Chevrolet Lumina APV/Venture, Honda Odyssey, Toyota Previa, Mazda MPV.

Unique Selling Points:

Spacious interior, flexible seating configurations, availability of all-wheel drive (AWD) in some configurations, comfortable ride, strong V6 engine options.

Design Philosophy:

Family-oriented, practical, and versatile people-mover, often featuring Stow 'n Go seating precursors and ample cargo capacity.

Target Audience:

Families, individuals requiring significant cargo space and passenger capacity.

📋 Manual Details

Primary Markets:

North America (USA, Canada)

Vehicle Variants Covered:

All trim levels and configurations of Dodge Caravan, Chrysler Town & Country, and Plymouth Voyager within the specified years.

Estimated Page Count:

Over 1500 (Estimated based on comprehensive workshop manual content for this generation)

Type:

Service and Repair Workshop Manual

Language:

English

Digital Format:

PDF Download

📖 Manual Coverage

Engine:

All gasoline and diesel engines (e.g., 2.5L I4, 3.0L V6 Mitsubishi, 3.3L V6, 3.8L V6 OHV)

Transmission:

Automatic Transmissions (e.g., A604 4-speed FWD, A670 4-speed FWD) and Manual Transmissions (if applicable, though less common for this era)

Drivetrain:

Front-Wheel Drive (FWD) systems, differentials, axles, CV joints.

Brakes:

Front and rear brake systems (disc/drum), ABS (Anti-lock Braking System) components and diagnostics.

Suspension Steering:

Front and rear suspension (struts, springs, control arms, bushings), power steering system, steering column, linkages.

Electrical:

Complete electrical system, wiring diagrams, lighting, ignition system, charging system, starter, battery, fuses, relays, power windows, locks, mirrors, climate control electronics.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, diagnosis, and repair.

Body Exterior:

Body panels, doors, hinges, latches, windows, exterior trim, bumpers, sunroof (if equipped).

Body Interior:

Interior trim panels, seats, seat belts, dashboard, console, headliner, carpets, interior accessories.

Diagnostics:

On-Board Diagnostics (OBD-I) system, diagnostic trouble codes (DTCs), troubleshooting charts.

Maintenance:

Routine maintenance procedures including oil changes, filter replacements, fluid checks and changes, tune-ups, spark plug replacement, belt and hose inspection/replacement.

Engine Repair:

Engine tune-up, cylinder head removal/installation, piston and connecting rod service, crankshaft service, valve train overhaul, timing belt/chain replacement, oil pump service, cooling system overhaul.

Transmission Service:

Transmission fluid and filter changes, transmission removal and installation, internal transmission component repair and overhaul.

Brake Service:

Brake pad and shoe replacement, brake rotor and drum servicing, brake caliper and wheel cylinder overhaul, brake fluid bleeding, ABS component replacement and bleeding.

Suspension Steering Repair:

Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack replacement, wheel alignment procedures.

Electrical Diagnosis Repair:

Wiring harness repair, component testing (starters, alternators, sensors), troubleshooting electrical faults using wiring diagrams, power window/lock actuator replacement.

HVAC Repair:

Refrigerant handling (with appropriate safety precautions), A/C compressor replacement, evaporator and condenser service, blower motor replacement, heater core replacement.

Body Work:

Door panel removal and installation, window regulator repair, bumper cover replacement, minor body panel repair, seal and weatherstripping replacement.

Troubleshooting:

Detailed troubleshooting guides for common symptoms and diagnostic procedures for various systems.

Depth Of Information:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures for all major systems.

Diagnostic Tools Required:

Covers procedures requiring standard hand tools, specialized automotive tools (e.g., timing tools, bearing pullers), and basic diagnostic equipment (multimeter, scan tool for OBD-I codes).

Repair Instructions:

Step-by-step instructions with torque specifications, clearances, and specialized procedures for accurate repairs.

Diagrams Illustrations:

Includes highly detailed, printable diagrams and illustrations for component identification, assembly, and disassembly.

📊 Manual Specifications

Digital File Type:

Adobe PDF

Printability:

High-resolution, suitable for clear printing of individual pages as needed.

Binding:

Not Applicable (Digital Download)

Paper Quality:

Not Applicable (Digital Download)

Text Searchability:

Assumed to be text-searchable within PDF, allowing for quick information retrieval.

Reader Software:

Adobe Acrobat Reader or compatible PDF viewer.

Compatibility:

Windows (95, 98, 98SE, 2000, NT, ME, XP, Vista, 7, 8) and Mac Computers.

⚙️ Engine Specifications

Engine 1 Displacement:

2.5 Liters (150.9 cu in)

Engine 1 Configuration:

Inline 4-Cylinder (I4)

Engine 1 Valvetrain:

Overhead Valve (OHV) or Single Overhead Cam (SOHC)

Engine 1 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 2 Displacement:

3.0 Liters (182.0 cu in)

Engine 2 Configuration:

V6 (Mitsubishi 6G72 SOHC)

Engine 2 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 3 Displacement:

3.3 Liters (201.5 cu in)

Engine 3 Configuration:

V6 (Chrysler OHV)

Engine 3 Valvetrain:

Overhead Valve (OHV)

Engine 3 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 4 Displacement:

3.8 Liters (230.7 cu in)

Engine 4 Configuration:

V6 (Chrysler OHV)

Engine 4 Valvetrain:

Overhead Valve (OHV)

Engine 4 Fuel System:

Multi-Point Fuel Injection (MPI)

Horsepower Range:

Approximately 100 hp (2.5L) to 180 hp (3.8L V6)

Torque Range:

Approximately 130 lb-ft (2.5L) to 240 lb-ft (3.8L V6)

🔧 Transmission

Transmission Type:

4-Speed Automatic (e.g., A604 for most V6 engines)

Transmission Options:

Some earlier models or specific configurations might have featured other automatic transmissions or less common manual options. (Manual transmission availability is very limited for this generation.)

Autostick:

Optional 'Autostick' feature on some models, allowing manual gear selection.

Automatic Transmission Fluid:

ATF+3 or ATF+4 (Chrysler specifications, check specific vehicle application for exact type, but ATF+3 is common for this era.)

📐 Dimensions

Length:

Approximately 175-180 inches (Short Wheelbase) / 190-195 inches (Long Wheelbase)

Width:

Approximately 72 inches

Height:

Approximately 68 inches

Seating Capacity:

7-8 passengers

Cargo Volume:

Highly configurable, with substantial cargo space behind the second and third rows, up to ~140-150 cu ft depending on configuration.

Curb Weight:

Approximately 3,500 - 4,200 lbs depending on engine and configuration.

🛡️ Safety Features

NHTSA Front Impact:

Mixed results for this generation; often received 'Acceptable' or 'Good' in frontal crash tests depending on specific year and testing methodology.

IIHS Side Impact:

Side impact performance varied; consult IIHS archives for specific year ratings.

ABS:

Anti-lock Braking System (ABS) available as an option or standard on higher trims.

Airbags:

Driver-side airbag standard; passenger-side airbag optional or standard on later models within the range.

Seat Belts:

Three-point seat belts for all outboard seating positions.

💡 Technology Features

Audio System:

AM/FM radio with cassette player, optional CD player, available premium audio systems with multiple speakers.

Cruise Control:

Standard or optional on most trims.

Trailer Tow Prep:

Wiring harnesses for trailer towing often available.

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 7,500 miles or 3-6 months, depending on oil type and driving conditions. Consult manual for specific recommendations.

Transmission Fluid Change:

Recommended every 30,000 - 60,000 miles, depending on driving conditions. Crucial for longevity of the A604 transmission.

Spark Plug Replacement:

Approximately 30,000 - 100,000 miles, depending on spark plug type (e.g., copper vs. platinum/iridium).

Engine Oil Type:

API Service SG, SH, or SJ; SAE 5W-30 or 10W-30 recommended (check owner's manual for specific viscosity based on temperature).

Coolant Type:

Ethylene Glycol based coolant (Mopar Antifreeze/Coolant, HOAT type often recommended, typically a green color for this era).

Power Steering Fluid:

ATF+3 or Mopar Power Steering Fluid.

Common Problems:

Transmission solenoid issues in A604, EGR valve clogging, intake manifold gasket leaks (3.3L/3.8L), head gasket leaks (3.0L Mitsubishi), power window regulator failures, rear climate control actuator issues.

Preventative Maintenance:

Regular transmission fluid changes, cleaning EGR valve, inspecting and replacing coolant hoses and belts proactively, checking for vacuum leaks.

📚 Vehicle History

Manufacturer Origin:

United States

Generation:

Second Generation (NS platform, 1991-1996).

Design Changes:

Introduced a more aerodynamic design, improved interior ergonomics, and became the benchmark for the minivan segment with innovations like available all-wheel drive and integrated child seats.

Manufacturing Locations:

Windsor, Ontario, Canada; St. Louis, Missouri, USA.

🏆 Awards & Recognition

Car Of The Year:

While specific awards for these exact years may vary, the Dodge Caravan/Plymouth Voyager lineage consistently ranked high in consumer satisfaction and segment leadership during this era, frequently appearing on 'Ten Best' lists for their class.

Consumer Reports:

Often cited for practicality and value, though reliability ratings could be mixed for certain components depending on the year and powertrain.