DODGE CARAVAN TOWN COUNTRY PLYMOUTH VOYAGER Service Repair Manual 1991-1993
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🏷️ Basic Information Identification Make: Dodge, Chrysler (Town & Country), Plymouth Model: Caravan, Town & Country, Voyager Generation: Second Generation (1991-1995) Codes Platform Code: NS 👋 Introduction Market Position Segment: Compact Minivan Target Audience: Families, individuals seeking versatile cargo and passenger transport. Competitive Analysis Key Competitors: Chevrolet Lumina APV, Pontiac Trans Sport, Ford Aerostar, Mazda MPV. Key Features Value Proposition: Affordable, practical, and versatile family transportation. Design Highlights: Front-wheel drive, spacious interior, sliding rear doors (on most models). 📋 Manual Details Coverage Areas Covered Makes: Dodge, Chrysler (Town & Country), Plymouth Covered Models: Caravan, Town & Country, Voyager Covered Years: 1991, 1992, 1993 Page Count Estimated Page Count: Approximately 1000+ (typical for comprehensive service manuals of this era) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Powertrain: Engine (3.3L V6, 3.0L V6), Transmission (Automatic - A604/41TE, Manual - Getrag G288) Chassis: Suspension (Front/Rear), Steering, Brakes (Hydraulic, ABS), Wheels, Tires Electrical: Battery, Charging System, Ignition System, Electric Starter, Lighting, Accessories, Wiring Diagrams, Switches Body: Body and Frame Repair, Doors, Glass, Interior Trim, Seating Comfort And Convenience: HVAC System, Power Windows, Power Locks, Seating Adjustments Procedures Included General Maintenance: Fluid Capacities, Lubrication, Inspection, Adjustment Engine Repair: Engine Removal/Installation, Cylinder Head/Valve Service, Cylinder/Piston Service, Crankcase Service, Crankshaft/Primary Shaft Service, Rebuilding Engine Transmission Repair: Transmission Service (Automatic and Manual), Gearshift Linkage, Sub-transmission Service Suspension And Steering: Front Wheel/Suspension Service, Rear Wheel/Suspension Service, Steering System Repair Brake System: Hydraulic Brake System Service, ABS System Diagnostics (if equipped) Electrical Diagnostics: Wiring Harness Repair, Component Testing, Troubleshooting Electrical Faults Troubleshooting: Comprehensive diagnostic procedures and common fault analysis Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for easy navigation. Print Quality Printable: Yes, allows printing of selected pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Compatibility Computer Compatibility: PC/MAC Compatible Features Zoom Functionality: Yes, allows zooming in/out of diagrams and text. Delivery Delivery Method: Instant Download via Email Link ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 3.3 L (3301 cc) Engine 1 Type: Naturally Aspirated V6 Engine 1 Bore X Stroke: 3.94 x 3.57 inches (100 x 90.7 mm) Engine 1 Compression Ratio: 8.4:1 Engine 1 Fuel Delivery: Multi-port Fuel Injection (MPI) Engine 1 Horsepower: Approx. 162 hp @ 4800 rpm Engine 1 Torque: Approx. 200 lb-ft @ 3600 rpm Optional Engine Engine 2 Displacement: 3.0 L (2972 cc) Engine 2 Type: Naturally Aspirated V6 (Mitsubishi 6G72 SOHC) Engine 2 Horsepower: Approx. 141 hp @ 4800 rpm Engine 2 Torque: Approx. 170 lb-ft @ 3000 rpm Fuel System Fuel Type: Unleaded Gasoline Fuel Tank Capacity: Approximately 18-20 gallons (varies slightly by model) 🔧 Transmission Automatic Automatic Transmission Model: Chrysler A604 (4-speed automatic) / 41TE (further development) Automatic Transmission Features: Electronically controlled, front-wheel drive transaxle. Automatic Transmission Fluid Type: ATF+3 or ATF+4 (refer to manual for specific fill) Manual Manual Transmission Model: Getrag G288 (5-speed manual) Manual Transmission Fluid Type: API GL-4 SAE 75W-90 synthetic gear oil (refer to manual for specific fill) 📐 Dimensions Exterior Wheelbase: Approximately 112.0 inches Length: Approximately 175.1 - 176.0 inches Width: Approximately 71.6 inches Height: Approximately 67.5 - 68.8 inches Weights Curb Weight: Approximately 3,500 - 3,900 lbs (varies by configuration) Gross Vehicle Weight Rating: Approximately 5,200 - 5,600 lbs 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver Side: Not rated or N/A for this era of testing standards. NHTSA Frontal Impact Passenger Side: Not rated or N/A for this era of testing standards. Active Features Anti Lock Brakes ABS: Available (Optional on some trims, standard on others). Passive Features Airbags: Driver-side airbag standard; passenger airbag optional on early models, becoming more common. Seat Belts: Three-point seat belts for all outboard seating positions. 💡 Technology Features Infotainment Audio System: AM/FM stereo radio with cassette player. Optional CD player available on some trims. Driver Assistance Cruise Control: Available. Connectivity Power Features: Power windows, power door locks, power mirrors (available). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 miles or 3-6 months (refer to manual for specific recommendations based on driving conditions). Transmission Fluid Change Interval: Every 30,000-60,000 miles (automatic), dependent on usage (refer to manual). Coolant Flush Interval: Every 30,000-50,000 miles or 2-3 years. Spark Plug Replacement: Typically around 60,000-100,000 miles, depending on spark plug type (platinum/iridium). Fluid Specifications Engine Oil Type: API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature). Coolant Type: Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 3 Hydraulic Brake Fluid. Known Issues Transmission Reliability: Early A604 transmissions could be prone to wear or failure, particularly if not maintained....
ATF+3 or ATF+4 (refer to manual for specific fill)
Manual
Manual Transmission Model:
Getrag G288 (5-speed manual)
Manual Transmission Fluid Type:
API GL-4 SAE 75W-90 synthetic gear oil (refer to manual for specific fill)
📐 Dimensions
Exterior
Wheelbase:
Approximately 112.0 inches
Length:
Approximately 175.1 - 176.0 inches
Width:
Approximately 71.6 inches
Height:
Approximately 67.5 - 68.8 inches
Weights
Curb Weight:
Approximately 3,500 - 3,900 lbs (varies by configuration)
Gross Vehicle Weight Rating:
Approximately 5,200 - 5,600 lbs
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver Side:
Not rated or N/A for this era of testing standards.
NHTSA Frontal Impact Passenger Side:
Not rated or N/A for this era of testing standards.
Active Features
Anti Lock Brakes ABS:
Available (Optional on some trims, standard on others).
Passive Features
Airbags:
Driver-side airbag standard; passenger airbag optional on early models, becoming more common.
Seat Belts:
Three-point seat belts for all outboard seating positions.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo radio with cassette player. Optional CD player available on some trims.
Driver Assistance
Cruise Control:
Available.
Connectivity
Power Features:
Power windows, power door locks, power mirrors (available).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (refer to manual for specific recommendations based on driving conditions).
Transmission Fluid Change Interval:
Every 30,000-60,000 miles (automatic), dependent on usage (refer to manual).
Coolant Flush Interval:
Every 30,000-50,000 miles or 2-3 years.
Spark Plug Replacement:
Typically around 60,000-100,000 miles, depending on spark plug type (platinum/iridium).
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature).
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 Hydraulic Brake Fluid.
Known Issues
Transmission Reliability:
Early A604 transmissions could be prone to wear or failure, particularly if not maintained. The 41TE addressed some of these issues. Torque converter shudder is a known symptom.
Engine Mounts:
Engine mounts can wear out over time, leading to vibration and clunking noises.
Cooling System:
Water pump leaks and radiator issues can occur. Overheating should be addressed promptly.
Exhaust System:
Exhaust components, particularly mufflers and catalytic converters, can rust and corrode.
Power Steering:
Leaks from the power steering pump or hoses can develop.
📚 Vehicle History
Brand Heritage
Manufacturer Legacy:
Dodge, Chrysler, and Plymouth were key players in the American automotive market, with Chrysler pioneering the minivan segment with the original Dodge Caravan.
Model Evolution
Generation Introduction:
The NS platform represented the second generation of the Dodge Caravan and Plymouth Voyager, introducing significant styling and engineering updates over the original S-platform.
Design Philosophy:
Focus on aerodynamics, interior packaging, and improved driving dynamics compared to the first generation.
Production
Assembly Locations:
Primarily Windsor, Ontario, Canada, and St. Louis, Missouri, USA.
🏆 Awards & Recognition
Recognitions
Automotive Journal Ratings:
Various automotive publications of the era praised the Caravan/Voyager for its interior space, practicality, and value, though often citing transmission concerns.