Dodge Caravan 1992 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1992 Codes Platform Code: AS (Second Generation) 👋 Introduction Market Position Vehicle Segment: Compact Minivan Segment Pioneer: The Dodge Caravan (and...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform Code:

AS (Second Generation)

👋 Introduction

Market Position

Vehicle Segment:

Compact Minivan

Segment Pioneer:

The Dodge Caravan (and its Plymouth Voyager sibling) pioneered the minivan segment in North America.

Competitive Analysis

Key Competitors:

Ford Aerostar, Chevrolet Astro/Safari, later models from Japanese manufacturers

Key Features

Design Philosophy:

Front-engine, front-wheel drive, unibody construction, sliding rear doors (introduced on the second generation), flexible seating configurations.

Target Demographic:

Families, individuals seeking versatile and practical transportation.

📋 Manual Details

Coverage Areas

Service Manual Type:

Factory Authorized Workshop Service Manual (WSM)

Language:

English

Format:

Downloadable Digital Format (likely PDF)

Page Count

Estimated Page Count:

Approximately 1000-1500 pages (typical for comprehensive WSMs of this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

2.5L 4-Cylinder (AMC/Mitsubishi 151), 3.3L V6 (EGA)

Engine Electrical:

Ignition system, fuel injection (MPI), starting and charging systems, engine control modules (ECM)

Transmission Manual:

A-525 Manual Transaxle

Transmission Automatic:

A-604 4-Speed Automatic Transaxle (Ultradrive)

Drivetrain:

Front-wheel drive components, axles, CV joints, differentials

Suspension:

Front independent suspension (MacPherson struts), rear torsion beam axle with trailing arms

Steering:

Power-assisted rack and pinion steering system

Brakes:

Front disc brakes, rear drum brakes, Anti-lock Braking System (ABS) for some models

Electrical System:

12-volt DC system, battery, alternator, lighting, wiring diagrams, fuses and relays

HVAC:

Heating, ventilation, and air conditioning (HVAC) system components and operation

Body And Frame:

Body construction, doors, windows, interior trim, exterior components, chassis

Safety Systems:

Seat belts, passive restraints (airbags were not standard in '92 Caravans), child seat anchors

Procedures Included

Routine Maintenance:

Oil changes, fluid checks and replacements, filter replacements, spark plug service

Diagnostics Troubleshooting:

System-specific diagnostic flowcharts, symptom-based troubleshooting guides, diagnostic trouble codes (DTCs)

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major systems

Rebuild Procedures:

Detailed instructions for rebuilding engines, transmissions, and other major components

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Specifications Tolerances:

Tightening torques, clearances, fluid capacities, pressure specifications, wear limits

Technical Depth

Diagnostic Tools:

Information on using diagnostic scan tools (OBD-I era), multimeters, and specialized equipment

Component Identification:

Clear identification of all parts and components with diagrams and part numbers where applicable

Special Tools:

List and description of any special tools required for specific repair procedures

📊 Manual Specifications

File Format

Digital Format Details:

Likely PDF with searchable text, high-resolution scans of original factory documentation

Print Quality

Scan Quality:

Professional quality scans, ensuring clarity and legibility of text and diagrams

Binding Type

Physical Equivalent Binding:

Original factory manuals were typically perfect bound or spiral bound

Paper Type

Physical Equivalent Paper:

Original manuals used durable, high-quality paper stock suitable for workshop environments

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

2.5 Liters

Engine 1 Configuration:

Inline 4-Cylinder

Engine 1 Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Engine 1 Horsepower Approx:

100-125 hp (depending on specific calibration)

Engine 1 Torque Approx:

135-150 lb-ft (depending on specific calibration)

Optional Engine

Engine 2 Displacement:

3.3 Liters

Engine 2 Configuration:

Engine 2 Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Engine 2 Horsepower Approx:

150-160 hp

Engine 2 Torque Approx:

185-195 lb-ft

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approximately 15-20 gallons (varies by model/configuration)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transaxle (A-525)

Optional

Optional Transmission Type:

4-Speed Automatic Transaxle (A-604 Ultradrive)

Features

Automatic Transmission Features:

Electronic control, torque converter lock-up

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 Gear Oil (verify specific manual)

Automatic Transmission Fluid:

ATF+3 (Chrysler spec) or equivalent Dexron III (verify specific manual)

📐 Dimensions

Exterior

Length:

Approximately 175-177 inches

Width:

Approximately 69 inches

Height:

Approximately 66-68 inches

Wheelbase

Wheelbase Length:

Approximately 112 inches

Weights

Curb Weight Approx:

3200-3600 lbs (depending on engine and configuration)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Not directly comparable to modern standards, minivan rollover tendency was a concern in this era.

Active Features

Optional Anti-lock Braking System (ABS) available on some models

Passive Features

Airbags:

Driver-side airbag became available on some models in the 1992 model year (optional or standard depending on trim)

Seat Belts:

Three-point seat belts for front occupants, lap belts for rear occupants (typical for the era)

💡 Technology Features

Infotainment

Audio System:

AM/FM radio, optional cassette player, optional CD player (rare for '92), multiple speaker configurations

Driver Assistance

Cruise Control:

Optional

Connectivity

Onboard Diagnostics:

OBD-I (On-Board Diagnostics - First Generation)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months (verify with manual, severe vs. normal service)

Tune Up Interval:

Typically around 30,000-60,000 miles, including spark plugs and filters (verify with manual)

Transmission Fluid Service:

Every 30,000-60,000 miles (verify with manual)

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 5W-30 or 10W-30 (verify specific viscosity based on climate)

Coolant Type:

Chrysler Conformance (long-life green ethylene glycol based)

Brake Fluid Type:

DOT 3

Known Issues

Engine 2.5L Issues:

Head gasket failures, oil leaks, timing belt service (critical)

Engine 3.3L V6 Issues:

Intake manifold gasket leaks, oil leaks, potential for sludge buildup if maintenance is neglected

Transmission A604 Issues:

Transmission control module (TCM) failures, solenoid issues, torque converter shudder (common in early Ultradrive units)

Suspension Issues:

Worn ball joints, tie rod ends, strut mounts, rear axle bushings

Electrical Issues:

Failing blower motor resistors, headlight switch issues, intermittent power to accessories

📚 Vehicle History

Brand Heritage

Dodge Legacy:

Dodge has a long history of producing practical and versatile vehicles.

Model Evolution

First Generation Introduction:

1984 (as Dodge Caravan and Plymouth Voyager)

Second Generation Introduction:

1991 (this generation, featuring updated styling and engineering)

Production

Manufacturing Locations:

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

🏆 Awards & Recognition

Recognitions

Import Car Of The Year Award For Minivan Segment:

While the Caravan itself didn't win Import Car of the Year (as it's a domestic product), its platform's success significantly shaped the automotive market and influenced international competitors.

Ratings

Car And Driver 10Best Mentions:

The Dodge Caravan/Plymouth Voyager were frequently recognized for their innovative design and utility in the automotive press during their initial generations.