🏷️ Basic Information

Make:

Plymouth

Model:

Duster

Production Years Covered:

1987-1994

Chassis Code:

VJ (for Duster and related Dodge Shadow/Plymouth Sundance models)

👋 Introduction

Segment:

Compact/Subcompact Hatchback (often positioned as an affordable and practical option).

Competitors:

Chevrolet Cavalier, Ford Escort, Honda Civic, Toyota Corolla, Nissan Sentra.

Selling Points:

Affordability, fuel efficiency (especially with 4-cylinder engines), practical hatchback utility, straightforward mechanicals suitable for DIY maintenance.

📋 Manual Details

Regions Covered:

North America (USA, Canada, Mexico)

Vehicle Variants:

Covers Plymouth Duster models equipped with 4-cylinder engines (2.2L, 2.5L) and V6 engines (3.0L Mitsubishi), with both manual and automatic transaxles.

Estimated Pages:

1500-2000 (typical for comprehensive shop manuals of this era)

Type:

Shop Service Repair Manual

Language:

English

Format:

PDF (Searchable with Index)

📖 Manual Coverage

Powertrain:

Engine mechanical (all variants), fuel system, ignition system, exhaust system, emissions controls, manual transaxle, automatic transaxle, clutch, driveshafts, differentials.

Chassis:

Suspension (front and rear), steering system, brake system (front disc, rear drum), wheels and tires.

Electrical:

Charging system, starting system, lighting system, instrument cluster, power windows, power locks, wipers, horn, diagnostic trouble codes (DTCs) for applicable systems, fuse and relay locations.

Body:

Exterior body panels, interior trim, doors, hood, trunk lid, glass, seats, body sealing.

HVAC:

Heating, ventilation, and air conditioning system components, operation, and basic troubleshooting.

Fuel & Emissions:

Fuel delivery, evaporative emissions control (EVAP), positive crankcase ventilation (PCV), exhaust gas recirculation (EGR) systems.

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation.

Repair:

Engine tune-ups, component replacement (alternator, starter, water pump), transmission service and repair, brake caliper and rotor replacement, suspension component replacement (shocks, struts, ball joints, tie rods), exhaust system repair, electrical component troubleshooting and replacement.

Troubleshooting:

Diagnostic procedures for common drivability issues, starting problems, electrical faults, and suspension noises, utilizing wiring diagrams and diagnostic flowcharts.

Diagnostics:

Diagnostic flowcharts for common problems, interpretation of diagnostic trouble codes (DTCs) where applicable, use of diagnostic tools of the era.

Depth:

Comprehensive. Covers from basic scheduled maintenance to in-depth engine, transmission, and electrical system diagnostics and repairs. Includes torque specifications, clearances, and detailed assembly/disassembly procedures.

Wiring Diagrams:

Detailed electrical wiring diagrams for all major systems, crucial for diagnosing electrical faults.

📊 Manual Specifications

Quality:

High-resolution scans for clear legibility. Searchable text allows for quick information retrieval.

Printability:

Printable pages, allowing for physical copies of specific sections or the entire manual.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

4 Cylinder Variant 1:

2.2L (135 cu. in.) Mopar 4-cylinder. Engine codes may include F4A or similar. Output typically around 96-100 hp.

4 Cylinder Variant 2:

2.5L (153 cu. in.) Mopar 4-cylinder (likely found in later models). Output typically around 105-110 hp.

V6 Variant 1:

3.0L (182 cu. in.) Mitsubishi 6G72 V6. Output typically around 141-144 hp.

Engine Design:

Inline 4-cylinder and V6 configurations, generally overhead valve (OHV) or single overhead cam (SOHC) depending on specific engine and origin (e.g., Mitsubishi V6).

Horsepower Range:

96 hp (2.2L 4-cyl) to 144 hp (3.0L V6)

Torque Range:

110 lb-ft (2.2L 4-cyl) to 164 lb-ft (3.0L V6)

Injection Type:

Electronic Fuel Injection (EFI) for all engines.

Fuel Type:

Unleaded Gasoline (87 octane typical recommendation).

🔧 Transmission

Manual Transaxle:

Typically a 5-speed manual transaxle.

Automatic Transaxle:

Typically a 3-speed automatic transaxle (e.g., A413, A470 depending on engine and year).

Transaxle Layout:

Front-wheel drive (FWD) transaxle.

📐 Dimensions

Length:

Approximately 165-168 inches

Width:

Approximately 66-67 inches

Height:

Approximately 53-54 inches

Curb Weight:

Approximately 2400-2700 lbs (depending on engine and options)

🛡️ Safety Features

NHTSA Crash Test:

Information may vary by year; typically not rated as highly as modern vehicles. Refer to specific year's NHTSA data if available.

Braking System:

Front disc brakes, rear drum brakes. Anti-lock Braking System (ABS) was an optional feature on some models.

Restraints:

Seat belts (lap and shoulder belts in front, lap belts in rear). Driver-side airbag became standard equipment in later model years (around 1990-1994) due to federal mandates.

💡 Technology Features

Audio System:

Basic AM/FM radio, optional cassette player. Some models may have had optional premium sound systems or equalizers.

ABS:

Optional Anti-lock Braking System on select models and years.

Cruise Control:

Optional cruise control system available on higher trim levels or as an option.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 to 5,000 miles or 3-6 months, depending on driving conditions. Refer to the manual for specific recommendations based on oil type.

Tune Up Interval:

Spark plug replacement generally recommended every 30,000 to 60,000 miles, depending on spark plug type.

Transmission Fluid Change:

Automatic transmission fluid and filter change typically recommended every 30,000 to 60,000 miles. Manual transmission fluid inspection and potential change at similar intervals.

Engine Oil:

Refer to manual, likely SAE 5W-30 or 10W-30 for most engines. API service classification SJ or SL (for later years). Specific part numbers for filters (e.g., Wix 51515, Fram PH8A for some 4-cyl, or equivalents for V6).

Coolant:

Ethylene Glycol-based antifreeze. Typically a 50/50 mix with distilled water. Mopar specific coolant may be recommended.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Automatic Transmission Fluid:

Chrysler ATF+3 or ATF+4 (for later model compatibility, though original spec might be earlier Mopar fluids). Check manual for precise spec.

Manual Transmission Fluid:

Refer to manual, likely gear oil or a specific manual transmission fluid.

Power Steering Fluid:

Refer to manual, typically Mopar power steering fluid or a compatible Dexron/Mercon type fluid.

Electrical:

Corrosion on grounds and connectors, failing wiper motors, intermittent issues with dashboard warning lights and power accessories.

Mechanical:

Head gasket leaks (especially on 2.2L and 2.5L engines), worn engine mounts, timing belt replacement on 4-cylinder engines, clutch wear on manual transmissions, strut mount issues.

Suspension Steering:

Premature wear of tie rod ends, ball joints, and wheel bearings; strut and shock absorber failure.

📚 Vehicle History

Plymouth Legacy:

Plymouth was known for offering affordable, no-frills vehicles. The Duster nameplate had a history with Plymouth in earlier decades, being revived for this front-wheel-drive platform.

Platform Sharing:

The Plymouth Duster shared its platform with the Dodge Shadow and Plymouth Sundance. Minor styling updates and feature additions occurred throughout its production run.

Manufacturing Plant:

Likely manufactured at Chrysler Corporation assembly plants in North America (e.g., Sterling Heights, Michigan).

🏆 Awards & Recognition

Industry Accolades:

While not a recipient of major 'Car of the Year' awards, the Duster was generally recognized as an affordable and competent compact car for its segment during its production years.