🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Year:

1992

Chassis Code:

AS/ES (Third Generation)

👋 Introduction

Market Position:

The Dodge Caravan was a segment-defining vehicle, often credited with creating the minivan category. For 1992, it represented a mature and popular family transport solution, competing with models like the Toyota Previa and Ford Aerostar. This manual is essential for owners and independent repair facilities maintaining this highly successful vehicle.

Competitive Analysis:

Chrysler's commitment to annual updates meant this manual would be the definitive guide for the 1992 model year, reflecting specific engineering changes and refinements over previous iterations. Owning this manual ensures access to the most accurate, year-specific repair and maintenance data, which is crucial given the unique nature of Chrysler's service documentation for each production year.

Key Features:

Uniquely tailored to the 1992 model year, this original service manual provides exhaustive details essential for accurate repairs and maintenance, differentiating it from generic or older manuals that might not reflect the specific engineering of this particular year.

Reason For Purchase:

Crucial for accurate repairs. Chrysler's yearly updates mean this 1992 manual has specific procedures and specifications for this exact model year, unlike generalized manuals or those for adjacent years which may contain outdated or incorrect information.

📋 Manual Details

Coverage Areas:

All major mechanical and electrical systems, including engine, transmission, drivetrain, suspension, steering, brakes, HVAC, body, and electrical diagnostics.

Page Count:

Approximately 800-1000 pages (estimated for a comprehensive original service manual of this era).

Manual Type:

Original Factory Service Manual / Shop Manual

Language:

English

Format:

Printed Publication

Binding Type:

Likely spiral-bound or perfect-bound for durability in a workshop environment.

📖 Manual Coverage

Systems Covered:

Engine Mechanical (2.5L 4-Cyl, 3.0L V6 Mitsubishi, 3.3L V6), Engine Performance & Emissions, Fuel System, Cooling System, Lubrication System, Ignition System, Starting & Charging System, Clutch, Automatic Transmission (3-Speed, 4-Speed), Drivetrain, Suspension (Front & Rear), Steering System, Brake System (Front Disc, Rear Drum, ABS optional), HVAC System, Body & Frame, Electrical System (Wiring Diagrams, Fuses, Relays, Lighting, Accessories), Restraint Systems (Airbags optional).

Electrical System Detail:

Extensive coverage of the electrical system, including fuse block layouts, relay functions, starter system, charging system (alternator), lighting circuits (headlights, taillights, interior), power windows, power locks, wiper systems, and horn. Detailed troubleshooting based on symptoms.

Procedures Included:

Routine maintenance, scheduled maintenance, diagnostics, troubleshooting charts, component removal and installation, repair procedures, component specifications, torque values, adjustments, rebuild procedures for major components.

Diagnostic Procedures:

Includes step-by-step diagnostic procedures for common and complex issues, fault code retrieval (if applicable), and component testing methods. Specific emphasis on electrical system diagnostics with detailed wiring diagrams.

Body And Trim Repair:

Procedures for interior trim removal and installation, exterior panel alignment, door and liftgate adjustment, bumper removal, and basic bodywork guidance.

Technical Depth:

Comprehensive. Covers everything from basic fluid changes and inspections to in-depth engine and transmission overhaul, advanced electrical diagnostics using wiring diagrams, and body repair procedures. Includes detailed specifications for precision work.

Diagnostic Tools Referenced:

References the use of specialized Chrysler diagnostic tools and procedures common to the era, such as analog multimeters and vacuum gauges for troubleshooting.

📊 Manual Specifications

File Format:

N/A (Printed)

Print Quality:

High Quality Original Print

Binding Type:

Original Publisher Binding (likely perfect bound or saddle-stitched for sections)

Paper Type:

Durable Offset Paper Stock

Completeness:

Complete Original Factory Service Manual. This is not a condensed or aftermarket guide, but the official documentation used by dealership technicians.

Part Number Reference:

Original Chrysler/Dodge part numbers for components and fluids often included or referenced.

⚙️ Engine Specifications

Primary Engine:

2.5L (153 cu. in.) SOHC Inline-4 (Fuel injected, Turbocharged option available)

Secondary Engine:

3.0L (181 cu. in.) SOHC V6 (Mitsubishi 6G72, Fuel injected)

Tertiary Engine:

3.3L (201 cu. in.) OHV V6 (Chrysler EGW, Fuel injected)

Engine Horsepower 2.5L:

100 hp @ 4400 rpm (non-turbo), 150 hp @ 4800 rpm (turbo)

Engine Torque 2.5L:

134 lb-ft @ 2400 rpm (non-turbo), 175 lb-ft @ 2400 rpm (turbo)

Engine Horsepower 3.0L:

141 hp @ 4800 rpm

Engine Torque 3.0L:

165 lb-ft @ 3600 rpm

Engine Horsepower 3.3L:

150 hp @ 4400 rpm

Engine Torque 3.3L:

180 lb-ft @ 2800 rpm

Engine Displacement Options:

2.5L I4, 3.0L V6, 3.3L V6

Fuel System:

Electronic Fuel Injection (EFI) for all engines.

Engine Codes 2.5L:

2.5L Non-Turbo: 400, 2.5L Turbo: 401

Engine Codes 3.0L:

3.0L V6: 403 (Mitsubishi)

Engine Codes 3.3L:

3.3L V6: 406 (Chrysler)

Ignition Timing 2.5L:

Refer to manual for specific timing adjustments, typically computer-controlled.

Valve Lash Adjustment:

Hydraulic lifters, typically non-adjustable (refer to manual for specific engine types).

🔧 Transmission

Standard Transmission:

3-Speed Automatic (A404/A413)

Optional Transmission:

4-Speed Automatic (A604 - Ultradrive, electronically controlled)

Transmission Features:

Front-wheel drive (FWD) standard. Ultradrive offered improved fuel economy and smoother shifts.

📐 Dimensions

Wheelbase:

112.1 inches

Length:

175.2 inches

Width:

71.4 inches

Height:

68.4 inches

Curb Weight:

Approx. 3,500 - 3,800 lbs (depending on configuration)

Gross Vehicle Weight Rating:

Approx. 5,200 lbs

Towing Capacity:

Refer to vehicle options/configuration; typically around 1,500-2,000 lbs with appropriate towing package.

Seating Capacity:

Configurable from 5 to 7 passengers depending on seating arrangement (2-2-3 or 2-3-2 configuration).

🛡️ Safety Features

NHTSA Rollover Rating:

N/A (Standardized rollover testing not fully implemented for this year)

Active Features:

Optional Anti-lock Braking System (ABS) for front wheels and later rear wheels on some models. Power-assisted front disc and rear drum brakes.

Passive Features:

Seat belts (manual lap and shoulder belts), optional driver-side airbag on some later 1992 models. Child safety seat anchors.

💡 Technology Features

Infotainment System:

Base AM/FM radio, optional cassette player, optional CD player (rare). Manual climate controls, no integrated infotainment screens.

Driver Assistance Features:

None beyond ABS availability. Cruise control was an option.

Connectivity:

N/A (No advanced connectivity features like Bluetooth or USB).

🔧 Maintenance

Oil Change Interval:

Every 3,000 miles or 3 months (typically for conventional oil of this era), or 6,000 miles/6 months with synthetic oil (if applicable/recommended by manufacturer).

Transmission Fluid Change Interval:

Every 30,000 miles or 24 months for typical use. Severe service intervals would be shorter.

Spark Plug Replacement:

Approx. 30,000 miles for standard plugs, potentially longer for platinum plugs if equipped.

Engine Oil Specification:

API Service SG or SH, SAE 5W-30 or 10W-30 (check specific engine recommendation)

Automatic Transmission Fluid Specification:

ATF+2 (or equivalent Mopar transmission fluid)

Coolant Specification:

Mopar Antifreeze/Coolant (Ethylene Glycol based, 50/50 mix with distilled water)

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent (refer to manual for exact specification).

Brake Fluid:

DOT 3 Brake Fluid

Common Issues 1992 Caravan:

Head gasket failures (especially on earlier V6s), transmission solenoid issues (Ultradrive), occasional electrical gremlins, exhaust manifold leaks, and rust on body panels, particularly around wheel wells and rocker panels.

Maintenance Schedule Summary:

Includes initial service, scheduled maintenance at 7,500 mile intervals (oil change, tire rotation), 15,000 mile intervals (air filter, cabin filter replacement), and 30,000 mile intervals (spark plugs, transmission fluid, coolant flush). Detailed breakdown for each interval.

📚 Vehicle History

Brand Heritage:

Dodge, as part of Chrysler Corporation, had a history of innovation in vehicle design and marketing. The Caravan's success cemented Chrysler's reputation for family-friendly, practical vehicles.

Model Evolution:

The 1992 model year falls within the third generation (1991-1995) of the Dodge Caravan. This generation saw significant redesigns including longer wheelbases, increased interior space, updated styling, and the introduction of the more powerful 3.3L V6 engine and the electronically controlled Ultradrive transmission.

Production Years:

First Generation: 1984-1990, Second Generation: 1991-1995, Third Generation: 1996-2000 (North America platform), etc. (This manual covers the 1991-1995 generation, specifically 1992).

Production Locations:

Primarily manufactured in the United States (e.g., St. Louis, Missouri; Windsor, Ontario, Canada for some periods).

🏆 Awards & Recognition

Car And Driver 10Best:

The Dodge Caravan (and Plymouth Voyager) was a frequent recipient of Car and Driver's '10Best' list in its early years, including the third generation, for its practicality and value.