Positioning:
The Dodge Caravan was a pioneering minivan that defined the segment. This manual provides the essential technical information for maintaining and repairing these popular family vehicles.
Competitors:
Ford Aerostar, Chevrolet Lumina APV/Venture, Plymouth Voyager (platform sharing)
Features:
Front-wheel drive, spacious interior, flexible seating arrangements, popular for families and commercial use.
Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body and Interior, Diagnostic Procedures, Maintenance
Type:
Factory Service Manual
Format:
Downloadable Digital File (likely PDF)
Engine Mechanical:
2.5L 4-Cylinder (MPI), 3.0L V6 (MPI), 3.3L V6 (MPI) - Overhaul, diagnosis, specifications
Engine Electrical:
Ignition, Fuel Injection (MPI), Starting, Charging, ECU diagnostics, wiring diagrams
Transmission Automatic:
A604 (41TE), A727 (32RH) - Service, diagnosis, fluid specifications, overhaul procedures
Drivetrain:
Front-wheel drive, Axles, CV joints, Differential (integrated in transmission)
Suspension:
Front MacPherson struts, Rear beam axle with trailing arms and Watt's linkage - Alignment, component replacement, specifications
Steering:
Power rack and pinion - Service, diagnosis, fluid specifications
Brakes:
Front discs, Rear drums, Power assist, ABS (if equipped) - Service, bleeding, pad/shoe replacement, rotor specifications
Electrical System:
Lighting, Wipers, Horn, Power windows/locks, Gauges, Fuses, Relays, Battery, Starter, Alternator, Wiring schematics
HVAC:
Air Conditioning, Heating, Ventilation - Component replacement, refrigerant handling, diagnosis
Body Interior:
Doors, Seats, Trim, Glass, Bumpers, Hood, Tailgate - Repair, adjustment, component replacement
Maintenance:
Oil changes, filter replacements, fluid checks and changes, tune-ups, belt/hose inspection and replacement
Diagnostics:
Troubleshooting charts for common drivability and electrical issues, DTC (Diagnostic Trouble Code) interpretation
Repair:
Component removal and installation for most major and minor systems, engine and transmission overhaul
Specifications:
Torque values, clearances, fluid capacities, electrical values, alignment angles
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures)
Engine Option 1:
2.5L 8-Valve SOHC Inline-4 (Turbocharged optional in earlier years, but typically naturally aspirated for '94)
Engine Option 1 Displacement:
2492 cc
Engine Option 1 Fuel System:
Multi-Point Fuel Injection (MPI)
Engine Option 2:
3.0L 12-Valve SOHC V6 (Mitsubishi 6G72 engine)
Engine Option 2 Displacement:
2972 cc
Engine Option 2 Fuel System:
Multi-Point Fuel Injection (MPI)
Engine Option 3:
3.3L 12-Valve SOHC V6 (Chrysler/Dodge)
Engine Option 3 Displacement:
3301 cc
Engine Option 3 Fuel System:
Multi-Point Fuel Injection (MPI)
Hp 2.5L 4Cyl:
Approx. 100-125 hp (depending on specific tune)
Torque 2.5L 4Cyl:
Approx. 130-145 lb-ft
Hp 3.0L V6:
Approx. 140-150 hp
Torque 3.0L V6:
Approx. 160-170 lb-ft
Hp 3.3L V6:
Approx. 150-160 hp
Torque 3.3L V6:
Approx. 180-195 lb-ft
NHTSA Frontal Impact Driver:
Not Rated (or Poor, depending on specific test and year reference)
NHTSA Frontal Impact Passenger:
Not Rated (or Poor, depending on specific test and year reference)
ABS:
Optional (Anti-lock Braking System) on rear wheels, or 4-wheel ABS on some models
Airbags:
Driver's side airbag standard on some models, optional on others. Passenger airbag not available for this year.
Seatbelts:
Front 3-point, rear lap and shoulder belts
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (check manual for specific engine/oil type)
Transmission Fluid Change:
Every 30,000-50,000 miles (check manual)
Spark Plugs:
Every 30,000-60,000 miles (depending on plug type)
Timing Belt:
Not applicable for 2.5L 4-cyl (uses timing chain). 3.0L V6 (Mitsubishi) uses timing belt, typically replaced at 60,000-90,000 miles.
Engine Oil Type:
API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for exact viscosity and capacity based on engine)
Coolant Type:
Chrysler's HOAT coolant (or equivalent green ethylene glycol based coolant, 50/50 mix)
Power Steering Fluid:
ATF+3 or equivalent power steering fluid
Common Problems:
Transmission issues (particularly A604/41TE solenoid pack failure, torque converter shudder), head gasket leaks on 3.3L V6, electrical gremlins (window motors, door locks), exhaust manifold cracks, rust (especially rear wheel wells and rocker panels).
Brand Origin:
Dodge is an American brand with a long history of producing trucks and performance vehicles, later expanding into passenger cars and minivans.
Generation:
Second Generation (1991-1995). This generation saw significant styling updates and mechanical refinements over the original.
Manufacturing Location:
Saltillo, Mexico; St. Louis, Missouri; Windsor, Ontario, Canada
