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Chrysler Dodge Caravan 1992 Service Repair Manual

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🏷️ Basic Information Identification Make: Chrysler/Dodge Model: Caravan Year: 1992 Codes Platform Code: NS (Third Generation) 👋 Introduction Market Position Market Segment: Minivan Competitive Analysis Key Competitors 1992: Ford Aerostar, Chevrolet Lumina APV/Venture, Mazda MPV, Toyota Previa Key Features Vehicle Highlights: Front-wheel drive platform, spacious interior, flexible seating configurations, family-oriented vehicle 📋 Manual Details Coverage Areas Primary Coverage: North America Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Printed Manual 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L V6, 3.0L V6), Transmission (3-speed automatic, 4-speed automatic), Fuel System, Exhaust System, Cooling System, Ignition System, Starting and Charging System Chassis: Suspension (Front & Rear), Steering System, Brakes (Front Disc, Rear Drum/Disc), Wheels & Tires Body & Electrical: Body Panels, Doors, Windows, Seats, HVAC System, Lighting, Wiring Diagrams, Fuses & Relays, Instrument Panel, Audio System, Body Control Modules Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks & Top-offs, Belt Inspections & Replacement, Brake Pad Replacement, Tire Rotation Repair: Engine Component Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis & Replacement, Body Panel Repair Troubleshooting: Diagnostic Trouble Codes (DTCs) interpretation, Symptom-based troubleshooting guides, Electrical circuit diagnostics, Mechanical component testing Technical Depth Depth: Comprehensive diagnostic procedures, Detailed repair instructions, Component specifications, Torque values, Alignment procedures, Wiring schematics 📊 Manual Specifications File Format Digital Format Details: Not Applicable (Printed) Print Quality Print Quality: High-quality paper, Clear text and diagrams Binding Type Binding Type: Typically Spiral-bound or perfect-bound for durability Paper Type Paper Type: Durable, often coated paper to resist shop oil and dirt ⚙️ Engine Specifications Primary Engine Engine Option 1: 3.3L (3301cc) OHV V6 (EGA) Engine Option 2: 3.0L (2972cc) SOHC V6 (Mitsubishi 6G72) Performance 3.3L V6 Horsepower: Approx. 162 hp @ 4800 rpm 3.3L V6 Torque: Approx. 190 lb-ft @ 3600 rpm 3.0L V6 Horsepower: Approx. 141 hp @ 5000 rpm 3.0L V6 Torque: Approx. 165 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Electronic Multi-port Fuel Injection (MPI) Engine Codes 3.3L V6 Engine Code: EGA 3.0L V6 Engine Code: 6G72 (Mitsubishi) 🔧 Transmission Standard Transmission Option 1: 3-Speed Automatic (A604/41TE Ultradrive) Optional Transmission Option 2: 4-Speed Automatic (A670) - Available with certain engines/trims Features Transmission Type Notes: The A604 Ultradrive was an early electronically controlled 4-speed automatic, though often referred to as a 3-speed due to its programming. Some manuals may refer to it as such. Fluid Specifications Automatic Transmission Fluid: Chrysler ATF+3 (or equivalent) 📐 Dimensions Exterior Wheelbase: Approx. 112.0 inches Length: Approx. 175.8 inches Width: Approx. 72.0 inches Height: Approx. 65.3 inches Weights Curb Weight Range: Approx. 3600 - 4000 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Frontal Impact Rating Driver: Not rated (vehicles from this era often did not have standardized ratings) NHTSA Frontal Impact Rating Passenger: Not rated Active Features ABS Availability: Optional on some trims Passive Features Airbag Availability: Driver-side airbag standard, passenger airbag optional on some trims Seat Belt Type: Front shoulder and lap belts, rear lap belts 💡 Technology Features Infotainment Audio System Options: AM/FM Radio, Cassette Player, Optional CD Player Driver Assistance Cruise Control: Standard on most trims Connectivity Diagnostic Ports: OBD-I (On-Board Diagnostics, First Generation) port, typically located under the dashboard. Scan tools specific to Chrysler's diagnostic protocols are required. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles or 3 months, whichever comes first (or 7,500 miles with synthetic oil) Transmission Fluid Change Interval: Every 30,000 miles or 2 years Spark Plug Replacement Interval 3.3L: Approx. 100,000 miles (if platinum plugs are used) Coolant Flush Interval: Every 24,000 miles or 2 years Fluid Specifications Engine Oil Type: SAE 5W-30 (API SG or higher) Coolant Type: Chrysler Type MS-8206 or equivalent (Ethylene Glycol based, green color) Brake Fluid Type: DOT 3 Known Issues Common Problem 1: Transmission issues (A604 'Ultradrive' solenoids, torque converter shudder, fluid leaks) Common Problem 2: Head gasket leaks on 3.3L V6 engine Common Problem 3: Power window motor failure, sliding door mechanism wear Common Problem 4: HVAC blower motor resistor failure, evaporator core leaks Common Problem 5: Cracked dashboard (less common than later models, but possible) 📚 Vehicle History Brand Heritage Chrysler Minivan Legacy: Chrysler is credited with inventing the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984. Model Evolution Third Generation Notes: The 1992 Caravan is part of the 'NS' platform, representing the second major redesign of the minivan. Introduced in late 1990 for the 1991 model year. Production Manufacturing Plant: Windsor, Ontario, Canada 🏆 Awards & Recognition Recognitions Car And Driver 10Best: The Dodge Caravan (and its Plymouth Voyager counterpart) was frequently recognized on Car and Driver's 10Best lists in its early generations for redefining the automotive segment.
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Chrysler Dodge Caravan 1992 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Chrysler/Dodge
Model:
Caravan
Year:
1992
Codes
Platform Code:
NS (Third Generation)
👋 Introduction
Market Position
Market Segment:
Minivan
Competitive Analysis
Key Competitors 1992:
Ford Aerostar, Chevrolet Lumina APV/Venture, Mazda MPV, Toyota Previa
Key Features
Vehicle Highlights:
Front-wheel drive platform, spacious interior, flexible seating configurations, family-oriented vehicle
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Printed Manual
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.3L V6, 3.0L V6), Transmission (3-speed automatic, 4-speed automatic), Fuel System, Exhaust System, Cooling System, Ignition System, Starting and Charging System
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Front Disc, Rear Drum/Disc), Wheels & Tires
Body & Electrical:
Body Panels, Doors, Windows, Seats, HVAC System, Lighting, Wiring Diagrams, Fuses & Relays, Instrument Panel, Audio System, Body Control Modules
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks & Top-offs, Belt Inspections & Replacement, Brake Pad Replacement, Tire Rotation
Repair:
Engine Component Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis & Replacement, Body Panel Repair
Troubleshooting:
Diagnostic Trouble Codes (DTCs) interpretation, Symptom-based troubleshooting guides, Electrical circuit diagnostics, Mechanical component testing
Technical Depth
Depth:
Comprehensive diagnostic procedures, Detailed repair instructions, Component specifications, Torque values, Alignment procedures, Wiring schematics
📊 Manual Specifications
File Format
Digital Format Details:
Not Applicable (Printed)
Print Quality
Print Quality:
High-quality paper, Clear text and diagrams
Binding Type
Binding Type:
Typically Spiral-bound or perfect-bound for durability
Paper Type
Paper Type:
Durable, often coated paper to resist shop oil and dirt
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
3.3L (3301cc) OHV V6 (EGA)
Engine Option 2:
3.0L (2972cc) SOHC V6 (Mitsubishi 6G72)
Performance
3.3L V6 Horsepower:
Approx. 162 hp @ 4800 rpm
3.3L V6 Torque:
Approx. 190 lb-ft @ 3600 rpm
3.0L V6 Horsepower:
Approx. 141 hp @ 5000 rpm
3.0L V6 Torque:
Approx. 165 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Electronic Multi-port Fuel Injection (MPI)
Engine Codes
3.3L V6 Engine Code:
EGA
3.0L V6 Engine Code:
6G72 (Mitsubishi)
🔧 Transmission
Standard
Transmission Option 1:
3-Speed Automatic (A604/41TE Ultradrive)
Optional
Transmission Option 2:
4-Speed Automatic (A670) - Available with certain engines/trims
Features
Transmission Type Notes:
The A604 Ultradrive was an early electronically controlled 4-speed automatic, though often referred to as a 3-speed due to its programming. Some manuals may refer to it as such.
Fluid Specifications
Automatic Transmission Fluid:
Chrysler ATF+3 (or equivalent)
📐 Dimensions
Exterior
Wheelbase:
Approx. 112.0 inches
Length:
Approx. 175.8 inches
Width:
Approx. 72.0 inches
Height:
Approx. 65.3 inches
Weights
Curb Weight Range:
Approx. 3600 - 4000 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Rating Driver:
Not rated (vehicles from this era often did not have standardized ratings)
NHTSA Frontal Impact Rating Passenger:
Not rated
Active Features
ABS Availability:
Optional on some trims
Passive Features
Airbag Availability:
Driver-side airbag standard, passenger airbag optional on some trims
Seat Belt Type:
Front shoulder and lap belts, rear lap belts
💡 Technology Features
Infotainment
Audio System Options:
AM/FM Radio, Cassette Player, Optional CD Player
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Diagnostic Ports:
OBD-I (On-Board Diagnostics, First Generation) port, typically located under the dashboard. Scan tools specific to Chrysler's diagnostic protocols are required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 3 months, whichever comes first (or 7,500 miles with synthetic oil)
Transmission Fluid Change Interval:
Every 30,000 miles or 2 years
Spark Plug Replacement Interval 3.3L:
Approx. 100,000 miles (if platinum plugs are used)
Coolant Flush Interval:
Every 24,000 miles or 2 years
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SG or higher)
Coolant Type:
Chrysler Type MS-8206 or equivalent (Ethylene Glycol based, green color)
Brake Fluid Type:
DOT 3
Known Issues
Common Problem 1:
Transmission issues (A604 'Ultradrive' solenoids, torque converter shudder, fluid leaks)
Common Problem 2:
Head gasket leaks on 3.3L V6 engine
Common Problem 3:
Power window motor failure, sliding door mechanism wear
Common Problem 4:
HVAC blower motor resistor failure, evaporator core leaks
Common Problem 5:
Cracked dashboard (less common than later models, but possible)
📚 Vehicle History
Brand Heritage
Chrysler Minivan Legacy:
Chrysler is credited with inventing the modern minivan segment with the original Dodge Caravan/Plymouth Voyager in 1984.
Model Evolution
Third Generation Notes:
The 1992 Caravan is part of the 'NS' platform, representing the second major redesign of the minivan. Introduced in late 1990 for the 1991 model year.
Production
Manufacturing Plant:
Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Dodge Caravan (and its Plymouth Voyager counterpart) was frequently recognized on Car and Driver's 10Best lists in its early generations for redefining the automotive segment.
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