Market Position:
Essential resource for owners and independent repair shops specializing in the popular Dodge Caravan/Chrysler Town & Country/Plymouth Voyager minivans of the early 1990s.
Competitive Analysis:
This manual provides factory-level detail comparable to or exceeding aftermarket manuals like Haynes or Chilton for this specific generation, covering both mechanical and electrical systems comprehensively.
Key Features:
A-Z repair coverage, detailed illustrations, electrical diagnostics, all models included.
Engine Mechanical:
Engine overhaul, timing, lubrication, cooling, fuel delivery, emissions control, exhaust system
Engine Electrical:
Ignition system, starter motor, alternator, engine sensors, ECU diagnosis
Transmission Manual:
Manual transmission overhaul, clutch, drive axles
Transmission Automatic:
Automatic transmission diagnosis, servicing, overhaul (A604/41TE)
Brakes:
Hydraulic system, power brakes, ABS (if equipped), drum/disc brake service
Suspension:
Front and rear suspension, steering system, alignment
Electrical System Body:
Lighting, wipers, horn, power windows, power locks, power seats, power mirrors, interior accessories
HVAC:
Heating, Ventilation, Air Conditioning system diagnosis and repair
Body And Frame:
Body panel repair, doors, windows, interior trim, underbody
Wiring Diagrams:
Complete electrical wiring schematics for all systems
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug service, belt replacement
Troubleshooting:
Diagnostic procedures for common and complex issues, symptom-based troubleshooting guides
Repair And Overhaul:
Step-by-step instructions for component removal, repair, and reinstallation
Diagnostics:
OBD-I diagnostic codes and procedures, sensor testing
Specifications And Tolerances:
Torque specifications, clearances, measurements for all components
Technical Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
Diagnostic Tools:
Information on required special tools and diagnostic equipment
Engine 1 Type:
2.5L (150 cu. in.) SOHC I4 (Turbocharged for some trims)
Engine 1 Displacement:
2497 cc
Engine 1 Bore X Stroke:
3.98 x 3.31 in. (101.1 x 84.1 mm)
Engine 1 Compression Ratio:
8.0:1 (Naturally Aspirated), 8.0:1 (Turbocharged)
Engine 1 Horsepower Na:
100 hp @ 4800 rpm (approx.)
Engine 1 Torque Na:
135 lb-ft @ 2800 rpm (approx.)
Engine 1 Horsepower Turbo:
150 hp @ 4800 rpm (approx.)
Engine 1 Torque Turbo:
170 lb-ft @ 3200 rpm (approx.)
Engine 2 Type:
3.0L (181 cu. in.) SOHC V6 (Mitsubishi 6G72)
Engine 2 Displacement:
2972 cc
Engine 2 Bore X Stroke:
3.50 x 3.15 in. (89.0 x 80.0 mm)
Engine 2 Compression Ratio:
8.9:1
Engine 2 Horsepower:
141 hp @ 4800 rpm (approx.)
Engine 2 Torque:
171 lb-ft @ 3000 rpm (approx.)
Engine 3 Type:
3.3L (201 cu. in.) OHV V6 (LA variant, related to AMC designs)
Engine 3 Displacement:
3295 cc
Engine 3 Bore X Stroke:
3.66 x 3.15 in. (93.0 x 80.0 mm)
Engine 3 Compression Ratio:
8.4:1
Engine 3 Horsepower:
162 hp @ 4800 rpm (approx.)
Engine 3 Torque:
190 lb-ft @ 3600 rpm (approx.)
Fuel System:
Electronic Fuel Injection (EFI) for all engines
Fuel Type:
Unleaded gasoline
Ignition System:
Distributorless Ignition System (DIS) or distributor-based ignition systems (depending on engine)
Standard Transmission:
5-speed Manual (for 2.5L I4)
Optional Transmission 1:
3-speed Automatic (TorqueFlite A727 - less common for these years)
Optional Transmission 2:
4-speed Automatic (Chrysler A604/41TE - prevalent for V6 models)
Transmission Features:
Front-wheel drive (FWD), lock-up torque converter on automatics.
Wheelbase:
112.1 inches (2847 mm) for long wheelbase versions
Length:
Varies by wheelbase and model, typically around 175-185 inches (4445-4700 mm)
Width:
70.2 inches (1783 mm)
Height:
68.3 inches (1735 mm)
Curb Weight:
Approx. 3400 - 3800 lbs (1542 - 1724 kg) depending on configuration
Cargo Volume:
Highly configurable with removable/stowable rear seats, offering significant cargo space.
NHTSA Ratings Driver Front Impact:
Likely 4-star (based on contemporary testing, specific year data may vary)
NHTSA Ratings Passenger Front Impact:
Likely 4-star (based on contemporary testing, specific year data may vary)
Active Safety Features:
Power-assisted front disc brakes, rear drum brakes. Optional Anti-lock Braking System (ABS) available on some models.
Passive Safety Features:
Front airbags (driver and passenger), three-point seat belts for all seating positions, child safety seat anchors (LATCH system not standard).
Infotainment System:
Basic AM/FM radio, optional cassette player, optional CD player. Analog climate controls.
Driver Assistance Features:
Limited by modern standards. Optional ABS on some models. Cruise control available.
Connectivity:
No advanced connectivity features (Bluetooth, USB, etc.) available.
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (recommended service interval, consult manual for specifics).
Transmission Fluid Change Interval:
Every 30,000-60,000 miles for automatic transmissions, depending on driving conditions (consult manual).
Spark Plug Replacement Interval:
Approximately 30,000-60,000 miles, depending on plug type (copper vs. platinum).
Timing Belt Replacement Interval:
For 3.0L V6: 60,000 miles. For 2.5L I4: check manual as some might have chains or belt.
Engine Oil Specification:
API SG or SH, SAE 5W-30 or 10W-30 (check manual for specific ambient temperature recommendations).
Transmission Fluid Specification Automatic:
Chrysler ATF+3 (or equivalent, e.g., Mopar ATF+3)
Coolant Specification:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 brake fluid.
Known Issues:
Transmission problems (especially A604 with solenoid failures, torque converter shudder), head gasket leaks on V6 engines, EGR valve issues, oil leaks from valve covers and oil pan, front suspension wear (ball joints, tie rods).
Electrical Gremlins:
Intermittent electrical issues, particularly related to power door locks, windows, and dashboard indicators, are not uncommon in vehicles of this age.
Brand Heritage:
Dodge, as part of Chrysler Corporation, has a long history of innovation in automotive design and manufacturing.
Model Evolution:
The Dodge Caravan, alongside its Chrysler and Plymouth counterparts, revolutionized the minivan segment in the mid-1980s. The 1991-1993 models represent the second generation of this highly successful platform, featuring updated styling, improved powertrains, and enhanced safety features.
Production Location:
Windsor, Ontario, Canada (Chrysler Canada assembly plant)
Sales Figures:
These minivans were among Chrysler's best-selling vehicles during this period, achieving high sales volumes annually.
