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1992 Dodge Caravan Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1992 Generation Generation Designation: Second Generation (RS Platform) Codes Platform Code: RS 👋 Introduction Market Position Vehicle Segment: Minivan Key Innovation: Revolutionized the family vehicle segment, offering unprecedented passenger and cargo versatility. Competitive Analysis Primary Competitors: Ford Aerostar, Chevrolet Lumina APV, Oldsmobile Silhouette, Pontiac Trans Sport Key Features Versatility: Removable rear seating, abundant interior space, front-wheel drive for superior traction. Powertrain Options: Available turbocharged 4-cylinder and smooth V6 engines. 📋 Manual Details Coverage Areas Primary Coverage: 1992 Dodge Caravan Secondary Coverage: Plymouth Voyager, Chrysler Town & Country (all RS platform variants for 1992) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Printed Binding Type: Staple-bound or perfect bound (typical for factory manuals) Paper Type: High-quality, durable paper stock suitable for workshop environments Print Quality: High-resolution, clear printing with sharp diagrams and illustrations 📖 Manual Coverage Systems Covered Engine: 2.5L Turbo I4 (156 cu in), 3.3L V6 (201 cu in) Transmission: 3-Speed Automatic (A604 FWD), 4-Speed Automatic (A670 FWD) Drivetrain: Front-Wheel Drive (FWD) Suspension: Front MacPherson Strut, Rear Torsion Beam Axle with Watt's Linkage Brakes: Front Disc, Rear Drum (with optional ABS) Steering: Power Assisted Rack and Pinion Electrical: 12V System, Charging System, Starting System, Lighting, Instruments, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Power Windows, Power Locks, Power Sliding Door (optional) Body: Body Panel Repair, Interior Trim, Exterior Trim, Doors, Windows, Seats, HVAC System, Audio System HVAC: Heating, Ventilation, Air Conditioning System Diagnosis and Repair Safety: Seat Belts, Airbag System (driver side only for this year), ABS (Anti-lock Braking System) Procedures Included Maintenance: Oil Change, Filter Replacement, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspection and Replacement, Brake Pad Replacement, Tire Rotation Diagnostics: Engine Performance Troubleshooting, Transmission Shifting Issues, Electrical System Faults, HVAC System Problems, Brake System Malfunctions Repair: Engine Component Replacement (e.g., Alternator, Starter, Water Pump), Transmission Overhaul and Repair, Brake System Component Replacement (e.g., Calipers, Rotors, Lines), Suspension Component Replacement (e.g., Struts, Ball Joints, Tie Rods), Electrical Component Replacement (e.g., Sensors, Actuators, Control Modules), Body Panel Repair and Replacement, Interior Component Repair Overhaul: Engine Overhaul Procedures (2.5L Turbo, 3.3L V6), Transmission Overhaul Procedures (A604, A670) Troubleshooting: Step-by-step diagnostic flowcharts and fault code interpretations (OBD-I based) Technical Depth Depth: Comprehensive Engine Rebuilds, Transmission Rebuilds, Electrical System Diagnostics, Body Repair, Suspension and Steering Overhaul Detail Level: Factory-level detail with torque specifications, clearances, wiring diagrams, and component testing procedures. ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.5 Liters (156 cubic inches) Engine 1 Configuration: Inline 4-Cylinder (I4) Engine 1 Aspiration: Turbocharged Engine 1 Horsepower: 150 hp @ 4800 rpm (approx.) Engine 1 Torque: 180 lb-ft @ 2400 rpm (approx.) Engine 1 Fuel System: Fuel Injection (MPI) Engine 1 Block Material: Cast Iron Engine 1 Head Material: Aluminum Optional Engine Engine 2 Displacement: 3.3 Liters (201 cubic inches) Engine 2 Configuration: V-Configuration (V6) Engine 2 Aspiration: Naturally Aspirated Engine 2 Horsepower: 162 hp @ 4800 rpm (approx.) Engine 2 Torque: 194 lb-ft @ 3600 rpm (approx.) Engine 2 Fuel System: Fuel Injection (MPI) Engine 2 Block Material: Cast Iron Engine 2 Head Material: Aluminum 🔧 Transmission Standard Transmission Type Standard: 3-Speed Automatic (A604 FWD) Optional Transmission Type Optional: 4-Speed Automatic (A670 FWD) Features Transmission Features: Lock-up torque converter, electronically controlled shifting (on A604 and A670) Fluid Specifications Transmission Fluid Type: ATF+3 (Chrysler Mopar) 📐 Dimensions Exterior Wheelbase: 112.1 inches Length: 175.3 inches Width: 71.2 inches Height: 68.4 inches Weights Curb Weight Min: 3550 lbs (approx.) Curb Weight Max: 3800 lbs (approx.) Cargo Cargo Volume Seats Up: 33.1 cu ft (behind 2nd seat) Cargo Volume Seats Down: 140.3 cu ft (max, all seats removed) 🛡️ Safety Features Ratings NHTSA Frontal Driver: Not rated (vehicle design predates standardized testing for frontal airbags) NHTSA Frontal Passenger: Not rated Active Features Active Braking: Optional Anti-lock Braking System (ABS) Passive Features Passive Restraints: Frontal airbags (driver only), three-point seatbelts for all outboard passengers, two-point seatbelts for center positions. Child Safety: LATCH system not standard; provisions for child seats available. 💡 Technology Features Infotainment Audio System: AM/FM Stereo radio with cassette player, optional CD player, and premium speaker systems available. Climate Control: Manual HVAC controls, optional automatic climate control available on higher trims. Driver Assistance Driver Assistance Features: Cruise control (standard on most models), optional Anti-lock Braking System (ABS). Connectivity Connectivity Features: None (vehicle predates modern connectivity standards like Bluetooth or USB). 🔧 Maintenance Service Intervals Oil Change Interval: 3,750 miles or 3 months (severe duty), 7,500 miles or 6 months (normal duty) Transmission Fluid Change: Inspect every 30,000 miles; change as needed based on inspection or every 60,000 miles (severe duty). Spark Plug Replacement: 30,000 miles (standard plugs), 60,000 miles (platinum plugs) Coolant Flush: Every 30,000 miles or 2 years Fluid...
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Tipo: Caravan
Proveedor:
SKU: 380832
Colecciones: ALL Dodge

DisponibilidadEn stock

Etiquetas: 1992 Caravan Cars Dodge Misc
1992 Dodge Caravan Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
1992
Generation
Generation Designation:
Second Generation (RS Platform)
Codes
Platform Code:
RS
👋 Introduction
Market Position
Vehicle Segment:
Minivan
Key Innovation:
Revolutionized the family vehicle segment, offering unprecedented passenger and cargo versatility.
Competitive Analysis
Primary Competitors:
Ford Aerostar, Chevrolet Lumina APV, Oldsmobile Silhouette, Pontiac Trans Sport
Key Features
Versatility:
Removable rear seating, abundant interior space, front-wheel drive for superior traction.
Powertrain Options:
Available turbocharged 4-cylinder and smooth V6 engines.
📋 Manual Details
Coverage Areas
Primary Coverage:
1992 Dodge Caravan
Secondary Coverage:
Plymouth Voyager, Chrysler Town & Country (all RS platform variants for 1992)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Printed
Binding Type:
Staple-bound or perfect bound (typical for factory manuals)
Paper Type:
High-quality, durable paper stock suitable for workshop environments
Print Quality:
High-resolution, clear printing with sharp diagrams and illustrations
📖 Manual Coverage
Systems Covered
Engine:
2.5L Turbo I4 (156 cu in), 3.3L V6 (201 cu in)
Transmission:
3-Speed Automatic (A604 FWD), 4-Speed Automatic (A670 FWD)
Drivetrain:
Front-Wheel Drive (FWD)
Suspension:
Front MacPherson Strut, Rear Torsion Beam Axle with Watt's Linkage
Brakes:
Front Disc, Rear Drum (with optional ABS)
Steering:
Power Assisted Rack and Pinion
Electrical:
12V System, Charging System, Starting System, Lighting, Instruments, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Power Windows, Power Locks, Power Sliding Door (optional)
Body:
Body Panel Repair, Interior Trim, Exterior Trim, Doors, Windows, Seats, HVAC System, Audio System
HVAC:
Heating, Ventilation, Air Conditioning System Diagnosis and Repair
Safety:
Seat Belts, Airbag System (driver side only for this year), ABS (Anti-lock Braking System)
Procedures Included
Maintenance:
Oil Change, Filter Replacement, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspection and Replacement, Brake Pad Replacement, Tire Rotation
Diagnostics:
Engine Performance Troubleshooting, Transmission Shifting Issues, Electrical System Faults, HVAC System Problems, Brake System Malfunctions
Repair:
Engine Component Replacement (e.g., Alternator, Starter, Water Pump), Transmission Overhaul and Repair, Brake System Component Replacement (e.g., Calipers, Rotors, Lines), Suspension Component Replacement (e.g., Struts, Ball Joints, Tie Rods), Electrical Component Replacement (e.g., Sensors, Actuators, Control Modules), Body Panel Repair and Replacement, Interior Component Repair
Overhaul:
Engine Overhaul Procedures (2.5L Turbo, 3.3L V6), Transmission Overhaul Procedures (A604, A670)
Troubleshooting:
Step-by-step diagnostic flowcharts and fault code interpretations (OBD-I based)
Technical Depth
Depth:
Comprehensive Engine Rebuilds, Transmission Rebuilds, Electrical System Diagnostics, Body Repair, Suspension and Steering Overhaul
Detail Level:
Factory-level detail with torque specifications, clearances, wiring diagrams, and component testing procedures.
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.5 Liters (156 cubic inches)
Engine 1 Configuration:
Inline 4-Cylinder (I4)
Engine 1 Aspiration:
Turbocharged
Engine 1 Horsepower:
150 hp @ 4800 rpm (approx.)
Engine 1 Torque:
180 lb-ft @ 2400 rpm (approx.)
Engine 1 Fuel System:
Fuel Injection (MPI)
Engine 1 Block Material:
Cast Iron
Engine 1 Head Material:
Aluminum
Optional Engine
Engine 2 Displacement:
3.3 Liters (201 cubic inches)
Engine 2 Configuration:
V-Configuration (V6)
Engine 2 Aspiration:
Naturally Aspirated
Engine 2 Horsepower:
162 hp @ 4800 rpm (approx.)
Engine 2 Torque:
194 lb-ft @ 3600 rpm (approx.)
Engine 2 Fuel System:
Fuel Injection (MPI)
Engine 2 Block Material:
Cast Iron
Engine 2 Head Material:
Aluminum
🔧 Transmission
Standard
Transmission Type Standard:
3-Speed Automatic (A604 FWD)
Optional
Transmission Type Optional:
4-Speed Automatic (A670 FWD)
Features
Transmission Features:
Lock-up torque converter, electronically controlled shifting (on A604 and A670)
Fluid Specifications
Transmission Fluid Type:
ATF+3 (Chrysler Mopar)
📐 Dimensions
Exterior
Wheelbase:
112.1 inches
Length:
175.3 inches
Width:
71.2 inches
Height:
68.4 inches
Weights
Curb Weight Min:
3550 lbs (approx.)
Curb Weight Max:
3800 lbs (approx.)
Cargo
Cargo Volume Seats Up:
33.1 cu ft (behind 2nd seat)
Cargo Volume Seats Down:
140.3 cu ft (max, all seats removed)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
Not rated (vehicle design predates standardized testing for frontal airbags)
NHTSA Frontal Passenger:
Not rated
Active Features
Active Braking:
Optional Anti-lock Braking System (ABS)
Passive Features
Passive Restraints:
Frontal airbags (driver only), three-point seatbelts for all outboard passengers, two-point seatbelts for center positions.
Child Safety:
LATCH system not standard; provisions for child seats available.
💡 Technology Features
Infotainment
Audio System:
AM/FM Stereo radio with cassette player, optional CD player, and premium speaker systems available.
Climate Control:
Manual HVAC controls, optional automatic climate control available on higher trims.
Driver Assistance
Driver Assistance Features:
Cruise control (standard on most models), optional Anti-lock Braking System (ABS).
Connectivity
Connectivity Features:
None (vehicle predates modern connectivity standards like Bluetooth or USB).
🔧 Maintenance
Service Intervals
Oil Change Interval:
3,750 miles or 3 months (severe duty), 7,500 miles or 6 months (normal duty)
Transmission Fluid Change:
Inspect every 30,000 miles; change as needed based on inspection or every 60,000 miles (severe duty).
Spark Plug Replacement:
30,000 miles (standard plugs), 60,000 miles (platinum plugs)
Coolant Flush:
Every 30,000 miles or 2 years
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 (all temperatures) or SAE 10W-30 (above 0°F)
Engine Oil Capacity:
4.5 Quarts (2.5L Turbo), 4.0 Quarts (3.3L V6) with filter
Coolant Type:
Ethylene Glycol (Chrysler Mopar Antifreeze/Coolant)
Coolant Capacity:
10.3 Quarts (2.5L), 11.5 Quarts (3.3L)
Brake Fluid Type:
DOT 3
Known Issues
Common Wear Items:
Struts, tie rod ends, ball joints, radiator, water pump, A/C compressor, power window regulators.
Engine Specific Issues:
2.5L Turbo: Head gasket failures, turbocharger oil leaks. 3.3L V6: Lifter noise, head gasket issues on early models.
Transmission Specific Issues:
A604/A670: Solenoid pack failures, torque converter clutch shudder, transmission fluid leaks.
Electrical Issues:
Instrument cluster failure, power door lock actuators, blower motor resistor.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing robust and practical vehicles, often with a focus on performance and utility.
Model Evolution
Caravan Introduction:
The original Dodge Caravan and Plymouth Voyager debuted in late 1983 for the 1984 model year, creating the minivan segment.
Second Generation:
The second generation (RS platform) was introduced for the 1991 model year, featuring a more aerodynamic design, improved powertrains, and enhanced safety features.
Production
Production Location:
Windsor, Ontario, Canada; St. Louis, Missouri, USA
Production Years Rs Platform:
1991-1995
🏆 Awards & Recognition
Recognitions
Critical Acclaim:
Consistently praised for its practicality and interior space upon introduction, widely recognized as a benchmark in its class.
Ratings
Consumer Reports Rating:
Variable; initial models often received good ratings for practicality, but reliability varied by powertrain and specific year.
Certifications
Emission Compliance:
Meets federal emission standards for the 1992 model year.
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