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Dodge Caravan 1994 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1994 Codes Platform Code: AS 👋 Introduction Market Position Positioning: The Dodge Caravan was a pioneering minivan that defined the segment. This manual provides the essential technical information for maintaining and repairing these popular family vehicles. Competitive Analysis Competitors: Ford Aerostar, Chevrolet Lumina APV/Venture, Plymouth Voyager (platform sharing) Key Features Features: Front-wheel drive, spacious interior, flexible seating arrangements, popular for families and commercial use. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body and Interior, Diagnostic Procedures, Maintenance Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual Language Language: English Format Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: 2.5L 4-Cylinder (MPI), 3.0L V6 (MPI), 3.3L V6 (MPI) - Overhaul, diagnosis, specifications Engine Electrical: Ignition, Fuel Injection (MPI), Starting, Charging, ECU diagnostics, wiring diagrams Transmission Automatic: A604 (41TE), A727 (32RH) - Service, diagnosis, fluid specifications, overhaul procedures Drivetrain: Front-wheel drive, Axles, CV joints, Differential (integrated in transmission) Suspension: Front MacPherson struts, Rear beam axle with trailing arms and Watt's linkage - Alignment, component replacement, specifications Steering: Power rack and pinion - Service, diagnosis, fluid specifications Brakes: Front discs, Rear drums, Power assist, ABS (if equipped) - Service, bleeding, pad/shoe replacement, rotor specifications Electrical System: Lighting, Wipers, Horn, Power windows/locks, Gauges, Fuses, Relays, Battery, Starter, Alternator, Wiring schematics HVAC: Air Conditioning, Heating, Ventilation - Component replacement, refrigerant handling, diagnosis Body Interior: Doors, Seats, Trim, Glass, Bumpers, Hood, Tailgate - Repair, adjustment, component replacement Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, tune-ups, belt/hose inspection and replacement Diagnostics: Troubleshooting charts for common drivability and electrical issues, DTC (Diagnostic Trouble Code) interpretation Repair: Component removal and installation for most major and minor systems, engine and transmission overhaul Specifications: Torque values, clearances, fluid capacities, electrical values, alignment angles Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures) 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans, clear text and diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Option 1: 2.5L 8-Valve SOHC Inline-4 (Turbocharged optional in earlier years, but typically naturally aspirated for '94) Engine Option 1 Displacement: 2492 cc Engine Option 1 Fuel System: Multi-Point Fuel Injection (MPI) Engine Option 2 Engine Option 2: 3.0L 12-Valve SOHC V6 (Mitsubishi 6G72 engine) Engine Option 2 Displacement: 2972 cc Engine Option 2 Fuel System: Multi-Point Fuel Injection (MPI) Engine Option 3 Engine Option 3: 3.3L 12-Valve SOHC V6 (Chrysler/Dodge) Engine Option 3 Displacement: 3301 cc Engine Option 3 Fuel System: Multi-Point Fuel Injection (MPI) Performance Hp 2.5L 4Cyl: Approx. 100-125 hp (depending on specific tune) Torque 2.5L 4Cyl: Approx. 130-145 lb-ft Hp 3.0L V6: Approx. 140-150 hp Torque 3.0L V6: Approx. 160-170 lb-ft Hp 3.3L V6: Approx. 150-160 hp Torque 3.3L V6: Approx. 180-195 lb-ft 🔧 Transmission Standard Standard Transmission: 4-speed Automatic (A604 - 41TE) Optional Optional Transmission: 3-speed Automatic (A727 - 32RH for some 2.5L models) Features Transmission Control: Electronically Controlled (for A604/41TE) Fluid Specifications Transmission Fluid Type: ATF+3 (Chrysler spec, equivalent to Dexron II/III for most purposes but use spec fluid) 📐 Dimensions Exterior Wheelbase: 111.9 inches (Standard Wheelbase), 119.3 inches (Long Wheelbase) Length: 176.5 inches (SWB), 185.4 inches (LWB) Width: 71.5 inches Height: 66.2 inches Weights Curb Weight: Approx. 3400-3800 lbs (depending on engine and configuration) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: Not Rated (or Poor, depending on specific test and year reference) NHTSA Frontal Impact Passenger: Not Rated (or Poor, depending on specific test and year reference) Active Features ABS: Optional (Anti-lock Braking System) on rear wheels, or 4-wheel ABS on some models Passive Features Airbags: Driver's side airbag standard on some models, optional on others. Passenger airbag not available for this year. Seatbelts: Front 3-point, rear lap and shoulder belts 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim level. Driver Assistance Cruise Control: Available on most models. Connectivity Connectivity Features: None in the modern sense (no Bluetooth, USB, or onboard navigation). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 3-6 months (check manual for specific engine/oil type) Transmission Fluid Change: Every 30,000-50,000 miles (check manual) Spark Plugs: Every 30,000-60,000 miles (depending on plug type) Timing Belt: Not applicable for 2.5L 4-cyl (uses timing chain). 3.0L V6 (Mitsubishi) uses timing belt, typically replaced at 60,000-90,000 miles. Fluid Specifications Engine Oil Type: API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for exact viscosity and capacity based on engine) Coolant Type: Chrysler's HOAT coolant (or equivalent green ethylene glycol based coolant, 50/50 mix) Power Steering Fluid: ATF+3 or equivalent power steering fluid Known...
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Dodge Caravan 1994 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Caravan
Year:
1994
Codes
Platform Code:
AS
👋 Introduction
Market Position
Positioning:
The Dodge Caravan was a pioneering minivan that defined the segment. This manual provides the essential technical information for maintaining and repairing these popular family vehicles.
Competitive Analysis
Competitors:
Ford Aerostar, Chevrolet Lumina APV/Venture, Plymouth Voyager (platform sharing)
Key Features
Features:
Front-wheel drive, spacious interior, flexible seating arrangements, popular for families and commercial use.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body and Interior, Diagnostic Procedures, Maintenance
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
2.5L 4-Cylinder (MPI), 3.0L V6 (MPI), 3.3L V6 (MPI) - Overhaul, diagnosis, specifications
Engine Electrical:
Ignition, Fuel Injection (MPI), Starting, Charging, ECU diagnostics, wiring diagrams
Transmission Automatic:
A604 (41TE), A727 (32RH) - Service, diagnosis, fluid specifications, overhaul procedures
Drivetrain:
Front-wheel drive, Axles, CV joints, Differential (integrated in transmission)
Suspension:
Front MacPherson struts, Rear beam axle with trailing arms and Watt's linkage - Alignment, component replacement, specifications
Steering:
Power rack and pinion - Service, diagnosis, fluid specifications
Brakes:
Front discs, Rear drums, Power assist, ABS (if equipped) - Service, bleeding, pad/shoe replacement, rotor specifications
Electrical System:
Lighting, Wipers, Horn, Power windows/locks, Gauges, Fuses, Relays, Battery, Starter, Alternator, Wiring schematics
HVAC:
Air Conditioning, Heating, Ventilation - Component replacement, refrigerant handling, diagnosis
Body Interior:
Doors, Seats, Trim, Glass, Bumpers, Hood, Tailgate - Repair, adjustment, component replacement
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, tune-ups, belt/hose inspection and replacement
Diagnostics:
Troubleshooting charts for common drivability and electrical issues, DTC (Diagnostic Trouble Code) interpretation
Repair:
Component removal and installation for most major and minor systems, engine and transmission overhaul
Specifications:
Torque values, clearances, fluid capacities, electrical values, alignment angles
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including diagnostic procedures)
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans, clear text and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
2.5L 8-Valve SOHC Inline-4 (Turbocharged optional in earlier years, but typically naturally aspirated for '94)
Engine Option 1 Displacement:
2492 cc
Engine Option 1 Fuel System:
Multi-Point Fuel Injection (MPI)
Engine Option 2
Engine Option 2:
3.0L 12-Valve SOHC V6 (Mitsubishi 6G72 engine)
Engine Option 2 Displacement:
2972 cc
Engine Option 2 Fuel System:
Multi-Point Fuel Injection (MPI)
Engine Option 3
Engine Option 3:
3.3L 12-Valve SOHC V6 (Chrysler/Dodge)
Engine Option 3 Displacement:
3301 cc
Engine Option 3 Fuel System:
Multi-Point Fuel Injection (MPI)
Performance
Hp 2.5L 4Cyl:
Approx. 100-125 hp (depending on specific tune)
Torque 2.5L 4Cyl:
Approx. 130-145 lb-ft
Hp 3.0L V6:
Approx. 140-150 hp
Torque 3.0L V6:
Approx. 160-170 lb-ft
Hp 3.3L V6:
Approx. 150-160 hp
Torque 3.3L V6:
Approx. 180-195 lb-ft
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic (A604 - 41TE)
Optional
Optional Transmission:
3-speed Automatic (A727 - 32RH for some 2.5L models)
Features
Transmission Control:
Electronically Controlled (for A604/41TE)
Fluid Specifications
Transmission Fluid Type:
ATF+3 (Chrysler spec, equivalent to Dexron II/III for most purposes but use spec fluid)
📐 Dimensions
Exterior
Wheelbase:
111.9 inches (Standard Wheelbase), 119.3 inches (Long Wheelbase)
Length:
176.5 inches (SWB), 185.4 inches (LWB)
Width:
71.5 inches
Height:
66.2 inches
Weights
Curb Weight:
Approx. 3400-3800 lbs (depending on engine and configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Not Rated (or Poor, depending on specific test and year reference)
NHTSA Frontal Impact Passenger:
Not Rated (or Poor, depending on specific test and year reference)
Active Features
ABS:
Optional (Anti-lock Braking System) on rear wheels, or 4-wheel ABS on some models
Passive Features
Airbags:
Driver's side airbag standard on some models, optional on others. Passenger airbag not available for this year.
Seatbelts:
Front 3-point, rear lap and shoulder belts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim level.
Driver Assistance
Cruise Control:
Available on most models.
Connectivity
Connectivity Features:
None in the modern sense (no Bluetooth, USB, or onboard navigation).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (check manual for specific engine/oil type)
Transmission Fluid Change:
Every 30,000-50,000 miles (check manual)
Spark Plugs:
Every 30,000-60,000 miles (depending on plug type)
Timing Belt:
Not applicable for 2.5L 4-cyl (uses timing chain). 3.0L V6 (Mitsubishi) uses timing belt, typically replaced at 60,000-90,000 miles.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for exact viscosity and capacity based on engine)
Coolant Type:
Chrysler's HOAT coolant (or equivalent green ethylene glycol based coolant, 50/50 mix)
Power Steering Fluid:
ATF+3 or equivalent power steering fluid
Known Issues
Common Problems:
Transmission issues (particularly A604/41TE solenoid pack failure, torque converter shudder), head gasket leaks on 3.3L V6, electrical gremlins (window motors, door locks), exhaust manifold cracks, rust (especially rear wheel wells and rocker panels).
📚 Vehicle History
Brand Heritage
Brand Origin:
Dodge is an American brand with a long history of producing trucks and performance vehicles, later expanding into passenger cars and minivans.
Model Evolution
Generation:
Second Generation (1991-1995). This generation saw significant styling updates and mechanical refinements over the original.
Production
Manufacturing Location:
Saltillo, Mexico; St. Louis, Missouri; Windsor, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Automobile Magazine All Star:
Often recognized in its class for utility and practicality during its production run.
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