Positioning:
The Dodge Caravan pioneered the minivan segment, offering unparalleled versatility and family-friendly utility. This manual caters to owners and technicians needing to maintain and repair these foundational vehicles.
Competitors:
Ford Aerostar, Chevrolet Astro/Voyager, Plymouth Voyager (shared platform), later Honda Odyssey.
Vehicle Highlights:
Front-wheel drive architecture, spacious interior, sliding rear doors (on some models), flexible seating arrangements.
Benefit To Owner:
Empowers owners with the knowledge to perform repairs, reduce labor costs, and ensure proper maintenance, thereby extending the vehicle's lifespan and maintaining its value.
Engine:
2.2L Turbo I4, 2.5L I4, 3.0L V6 (Mitsubishi)
Transmission:
3-speed automatic (A604 FWD), 4-speed automatic (A670 FWD)
Drivetrain:
Front-Wheel Drive (FWD)
Brakes:
Front disc, rear drum (ABS optional on later models)
Suspension:
Independent front suspension (MacPherson struts), Torsion beam rear axle with trailing arms
Steering:
Power-assisted rack and pinion
Electrical:
Battery, alternator, starter, ignition system, lighting, instrumentation, power windows/locks/mirrors (if equipped)
HVAC:
Air conditioning, heating, ventilation system diagnosis and repair
Fuel:
Fuel tank, fuel pump, fuel injection system (EFI)
Exhaust:
Exhaust manifold, catalytic converter, muffler, pipes
Body:
Body panels, doors, glass, interior trim, seat mechanisms
Chassis:
Frame, subframes, body-to-chassis mounting
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement
Engine Repair:
Engine overhaul, piston and ring replacement, cylinder head repair, timing belt/chain service
Transmission Repair:
Transmission overhaul, clutch replacement (if manual), torque converter service, solenoid replacement
Brake Service:
Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper/wheel cylinder overhaul, bleeding
Suspension And Steering:
Strut/shock absorber replacement, ball joint service, tie rod end replacement, power steering pump/rack replacement
Electrical Diagnostics:
Troubleshooting wiring diagrams, component testing, common electrical faults
HVAC Service:
Refrigerant system service, blower motor replacement, heater core replacement, A/C compressor replacement
Fuel System Repair:
Fuel injector cleaning/replacement, fuel pump replacement, fuel pressure testing
Exhaust System Repair:
Muffler/catalytic converter replacement, gasket replacement, leak repair
Body And Interior:
Door panel removal, window regulator repair, seat adjustment mechanism repair, minor body panel repair
Troubleshooting:
Diagnostic charts, common problems and solutions, symptom-based troubleshooting
Specifications:
Torque specifications, fluid capacities, engine clearances, electrical values
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Engine Options:
2.2L Turbo I4, 2.5L Naturally Aspirated I4, 3.0L V6 (Mitsubishi 6G72)
Horsepower Range:
Approx. 96 hp (2.5L NA) to 146 hp (2.2L Turbo/3.0L V6)
Torque Range:
Approx. 130 lb-ft (2.5L NA) to 160 lb-ft (2.2L Turbo/3.0L V6)
Fuel Delivery:
Electronic Fuel Injection (EFI) for all engine variants.
Cooling Type:
Pressurized liquid cooling system with radiator, fan, and water pump.
Ignition Type:
Electronic Ignition (Distributorless ignition on some later models).
Transmission Options:
3-speed Torqueflite automatic (A604) was standard on many early models. 4-speed automatic (A670) became more common later.
Manual Transmission Availability:
Manual transmissions were generally not offered or were exceedingly rare in North American market Caravans of this generation.
Automatic Transmission Features:
Electronic controls, lock-up torque converter for improved fuel efficiency.
Transmission Fluid Type:
Chrysler ATF+3 (or equivalent recommended for the specific transmission model).
Length:
Approximately 176-177 inches (standard wheelbase).
Width:
Approximately 67-68 inches.
Height:
Approximately 64-65 inches.
Seating Capacity:
Typically 5-7 passengers, depending on configuration.
Cargo Volume:
Highly configurable, with significant cargo space when rear seats are removed or folded.
Curb Weight:
Approximately 3,000 - 3,400 lbs depending on engine and options.
Towing Capacity:
Limited; typically not designed for heavy towing without specific towing packages.
Oil Change Interval:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Refer to manual for exact mileage.
Timing Belt Replacement:
Crucial for 2.2L and 2.5L engines. Interval varies, but typically around 60,000-90,000 miles. V6 engines typically have a timing chain.
Engine Oil Type:
Refer to manual; typically 10W-30 or 10W-40 for gasoline engines. Viscosity may vary by temperature.
Coolant Type:
Ethylene glycol-based coolant (e.g., Mopar Antifreeze/Coolant).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Problems:
Transmission issues (especially early automatics), head gasket leaks (on certain engine variants), rust (especially in salt-belt regions), aging electrical components, dashboard warp/cracking, suspension wear.
Spark Plugs:
Spark plug part numbers vary by engine. Consult manual or parts catalog. Typical replacement interval: 30,000-60,000 miles.
Air Filter Part Number:
Varies by engine; example for 2.5L might be Wix 42140 or equivalent. Consult manual/catalog.
Oil Filter Part Number:
Varies by engine; example for 2.2/2.5L might be Wix 51515 or equivalent. Consult manual/catalog.
Dodge Legacy:
Dodge, as part of Chrysler Corporation, has a long history of innovation in automotive design and engineering, particularly with the introduction of the minivan.
First Generation:
The 1984 Dodge Caravan, along with its Plymouth Voyager counterpart, revolutionized the automotive market by creating the modern minivan segment. This first generation ran from 1984 to 1990.
Manufacturing Locations:
Primarily St. Louis, Missouri, USA.
Production Years:
1984-1990 (First Generation)
