🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Generation:

Second Generation (1991-1995)

Platform:

Chrysler Minivan Platform (AS)

Vin Code:

A-body (for front-wheel drive applications)

👋 Introduction

Positioning:

The Dodge Caravan (and its Plymouth Voyager and Chrysler Voyager siblings) defined the minivan segment in North America, offering unparalleled practicality, versatility, and passenger comfort. This manual covers the second generation, a period of refinement and enhancement for the segment-defining vehicle.

Competitors Covered By Vehicle:

Ford Aerostar, Chevrolet Lumina APV/Venture/Trans Sport, Mazda MPV, Toyota Previa.

Vehicle Highlight:

Front-wheel drive, sliding rear passenger door (introduced in this generation), optional all-wheel drive, spacious interior with flexible seating configurations, comfortable ride.

Value To Owner:

Empowers owners to perform essential maintenance, diagnose common issues, and undertake repairs, leading to significant cost savings and extended vehicle lifespan. Provides authoritative technical information directly from the manufacturer.

📋 Manual Details

Years Covered:

1991, 1992, 1993, 1994, 1995

Trims Covered:

All trims (e.g., SE, LE, ES, Sport, Grand Caravan)

Estimated Page Count:

1500-2000+ pages (typical for comprehensive factory service manuals of this era)

Type:

Factory Service Workshop Repair Manual

Language:

English

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, transmission (automatic and manual if applicable), drivetrain components (CV joints, axles, differentials).

Chassis:

Suspension systems (front and rear), steering system, brake system (front and rear, ABS if equipped), wheels and tires.

Body And Interior:

Body construction, exterior trim, interior trim, seating, doors, windows, sunroof, liftgate, HVAC system, body electrical systems (lighting, power windows, locks, mirrors).

Electrical And Electronics:

Wiring diagrams, fuse and relay information, battery and charging system, starter system, instrument cluster, audio system, cruise control, power accessories.

Maintenance:

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

Diagnostics:

Troubleshooting guides, diagnostic charts, symptom analysis, fault code interpretation (where applicable).

Repair:

Step-by-step repair instructions for all major mechanical and electrical components, including engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, etc.

Installation:

Instructions for component replacement and installation, including torque specifications.

Depth:

Comprehensive: Covers routine maintenance, basic diagnostics, major component overhauls, and detailed repair procedures. Suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable PDF for easy navigation of topics and keywords.

Print Readability:

High-resolution scans suitable for printing, with clear diagrams and text.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

2.5L I4 (Turbocharged and Naturally Aspirated), 3.0L V6 (Mitsubishi 6G72), 3.3L V6 (Chrysler EPT engine), 3.8L V6 (Chrysler EPT engine).

Horsepower Torque:

Varies by engine: 2.5L I4 (approx. 100-120 hp), 3.0L V6 (approx. 141 hp), 3.3L V6 (approx. 150-160 hp), 3.8L V6 (approx. 162-180 hp). Torque figures also vary accordingly.

Injection Type:

Multi-point fuel injection (MPFI) for most models. Carbureted for some early 2.5L engines.

ECU Type:

OBD-I (On-Board Diagnostics - First Generation) with increasing reliance on electronic control units (ECUs) for fuel and ignition management.

Coolant Type:

Ethylene glycol-based coolant (e.g., Mopar Antifreeze/Coolant 5-Year Formula or equivalent). Consult manual for specific OE part numbers and mix ratios.

Oil Capacity:

Typically 4.0-5.0 quarts (3.8-4.7 liters) depending on engine. Consult manual for exact capacity and specific oil viscosity grades (e.g., 5W-30, 10W-30).

🔧 Transmission

Transmission Options:

Commonly paired with a 3-speed or 4-speed automatic transmission (e.g., A604, A670, A606). Manual transmissions were less common but might be available on base models.

Optional Transmissions:

All-wheel drive (AWD) option available on certain models, typically paired with the automatic transmission.

Transmission Fluid Type:

ATF+3 or equivalent (e.g., Mopar ATF+3 Automatic Transmission Fluid). Refer to manual for specific fluid specifications and part numbers.

Fluid Capacity:

Approximately 7-9 quarts (6.6-8.5 liters) for automatic transmissions. Consult manual for exact capacity and filling procedure.

📐 Dimensions

Wheelbase:

Standard wheelbase approximately 112.1 inches. Grand Caravan wheelbase approximately 119.3 inches.

Length:

Varies by model (standard vs. Grand). Standard Caravan approx. 176.3 inches. Grand Caravan approx. 183.1 inches.

Width:

Approx. 70.4 inches (excluding mirrors).

Passenger Capacity:

Typically seats 7 passengers with three rows of seating.

Cargo Volume:

Highly configurable, offering significant cargo space behind the second and third rows. Specific volumes available in the manual.

Curb Weight:

Varies significantly by configuration, engine, and trim level, typically ranging from 3,500 to 4,500 lbs (1,588 to 2,041 kg).

Towing Capacity:

Available with optional towing packages. Consult manual for specific towing limits.

🛡️ Safety Features

NHTSA Ratings:

While official NHTSA ratings for this specific period might be less detailed by today's standards, the vehicle was designed with occupant safety in mind. Refer to manual for specific structural information.

ABS:

Anti-lock Braking System (ABS) was available as an option on many models, particularly those with V6 engines and higher trims.

Traction Control:

Traction control systems were not common in this generation, but some later models might have incorporated basic electronic stability aids.

Airbags:

Driver-side airbag was standard on most models by the mid-1990s. Passenger airbags were optional or not available on all trims.

Seat Belts:

Three-point seat belts for all occupants, including shoulder belts for front and second-row passengers. Third-row seating often featured lap belts or three-point belts depending on configuration.

💡 Technology Features

Audio System:

Factory AM/FM cassette players, often with optional CD players. Premium audio systems with more speakers available on higher trims. Manual covers removal, installation, and troubleshooting of these units.

Cruise Control:

Cruise control was a common option, covering its operation, diagnosis, and repair. Controls are typically mounted on the steering wheel.

Remote Entry:

Keyless entry systems became more prevalent towards the end of this generation. The manual details their operation and potential servicing.

Power Accessories:

Power windows, power door locks, power mirrors, and power sliding doors (on some models) are covered in detail, including their electrical circuits and common failure points.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used. Consult manual for specific recommendations.

Transmission Fluid Change Interval:

Recommended every 30,000-50,000 miles (48,000-80,000 km) or as per severe service schedule. Crucial for longevity of the automatic transmission.

Spark Plug Replacement:

Intervals vary by engine type, generally between 30,000-100,000 miles. Consult manual for specific plug type (e.g., copper, platinum, iridium) and interval.

Power Steering Fluid:

Mopar Power Steering Fluid or equivalent. Consult manual for specific part number and type.

Brake Fluid Type:

DOT 3 brake fluid. Ensure adherence to quality standards and periodic flushing as per manual recommendations.

Common Problems Powertrain:

Transmission solenoid issues (especially in early 4-speed automatics), head gasket leaks (particularly on the 3.3L and 3.8L V6 engines), timing belt replacement (on the 3.0L Mitsubishi V6), and exhaust manifold leaks.

Common Problems Chassis Electrical:

Power door lock actuators, window regulators, rear wiper motor failures, dashboard illumination issues, and occasional problems with the ABS sensor or module.

Common Problems HVAC:

A/C compressor failures, blend door actuator issues, and HVAC blower motor resistor failures.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge played a pivotal role in popularizing the minivan segment, with the Caravan being its flagship offering. This generation built upon the success of the original K-car based minivans.

Generation Introduction:

The second generation, launched for the 1991 model year, introduced significant updates including a longer wheelbase option (Grand Caravan), a more aerodynamic design, and the highly sought-after sliding rear passenger door, a major convenience feature.

Manufacturing Locations:

Primarily manufactured in North America, with key plants including Windsor, Ontario, Canada, and St. Louis, Missouri, USA.

Market Dominance:

The Caravan and its siblings consistently dominated the minivan sales charts throughout the 1990s, solidifying their position as leaders in the segment.

🏆 Awards & Recognition

Popular Mechanics Editors Choice:

The Dodge Caravan was frequently recognized by automotive publications for its innovation and practicality. While specific awards for these exact years need verification, the model consistently received accolades in its segment.

Consumer Reports Rankings:

Consumer Reports often provided detailed reviews and reliability ratings for the Caravan. This manual's technical information is crucial for addressing reported reliability concerns.

Oem Certification:

This is a 'Factory Service Workshop Manual,' meaning it is the official documentation provided by the manufacturer (Chrysler Corporation, parent of Dodge) for their dealership technicians. This guarantees accuracy and adherence to OEM standards.