1992 dodge grand dodge caravan se repair manual

Dodge Caravan Workshop Manual L 2. Best Car Battery Tester. Best Electric Garage Heater. Dodge - Caravan - Owners Manual - - Dodge - Grand Caravan - Owners Manual - - The Best Underhood Work Light. Dodge - Auto - dodge-grand-caravanguide-d-utilisateur Dodge - Grand Caravan - Sales Brochure - - Brochure 27 Pages. Dodge - Grand Caravan - Sales Brochure - - 2. Brochure 71 Pages. Brochure 2 Pages. Nissan - Auto - nissan-nvcaravannv Dodge - Auto - dodge-caravanowner-s-manual Dodge - Caravan - Sales Brochure - - Brochure 9 Pages.

Dodge - Grand Caravan - Sales Brochure - - 4. Brochure 23 Pages. Brochure 30 Pages. Brochure 34 Pages. Brochure 58 Pages. Dodge - Grand Caravan - Sales Brochure - - 5. Brochure 41 Pages. Brochure 13 Pages. Brochure 8 Pages. Brochure 20 Pages. Brochure 6 Pages. All approved products have the NLGI sym- bol on the label. At the bottom NLGI symbol is the usage and quality identification letters.

The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality. Some components are sealed and permanently lubricated. Rubber bush- ings can deteriorate or limit damping ability if lubri- cated.

Electrical systems can be damaged on either vehicle. BLACK clamp to nega- tive terminal -. Review all warnings in this procedure. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool 15 min. Discon- nect RED cable clamp from battery positive terminal.

When using a wheel lift towing device, be sure the unlifted end of disabled vehicle has at least mm 4 in. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees.

A towed vehicle should be raised until lifted wheels are a minimum mm 4 in from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road.

If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors. The steering column must be unlocked and gear selector in neutral.

CAUTION: Do not damage brake lines, exhaust sys- tem, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle.

Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers.

The gear selector must be in neutral position. If none of these apply to you then change your oil every 12 kilometers 7, miles or 6 months, whichever comes first. If none of these apply and the vehicle is in commer- cial type service such as, Police, Taxi or Limousine used for highway driving of 40 kilometers 25 miles or more between stations, the engine oil should be changed every 8 kilometers 5, miles or 6 months.

On a Chrysler Corporation vehicle an extended break-in period is not required. Hard acceleration and high engine rpm in lower gears should be avoided. Engine or Turbocharger failure can result. The factory fill engine oil is a high quality, energy conserving, crankcase lubricant. The Recommended SAE Viscosity Grades chart defines the viscosity grades that must be used based on temperature in the region where vehicle is operated Fig.

The API symbol Fig. SAE 5W engine oil is not recommended for use in 2. Inspect engine oil level approximately every kilometers miles. Position vehicle on level sur- face. With engine OFF, allow enough time for oil to settle to bottom of crankcase, remove engine oil level indicator dipstick and wipe clean. Install dipstick and verify it is seated in the tube. Remove dipstick, with handle above tip, take oil level reading Fig. Refer to Hoisting and Jacking Recommendations in this group.

Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. A replacement filter must be designed to with- stand kPa psi of internal pressure. Remove filter from vehicle. Wipe off oil residue from below oil filter adapter. When gasket makes contact with sealing surface, tighten filter one full turn. If necessary use a filter wrench, do not over tighten. Inspect for oil leaks. Do not operate vehicle without proper concentra- tion of recommended ethylene glycol coolant, high running temperatures and cooling system corrosion can result.

The engine cooling system will develop internal pres- sure of 97 to kPa 14 to 18 psi at normal operating temperature. Allow the vehicle approximately one half hour to cool off before opening the cooling system. As an indicator of pressure, squeeze the upper radiator hose between index finger and thumb.

If it collapses with little effort the system would have low internal pres- sure and should be safe to open to the first safety notch of the radiator cap. Refer to Group 7, Cooling System. Coolant recovery tank level should read between the MIN and MAX marks, located on the side of recovery tank, when the engine is at normal operating temperature. Normal coolant level maintenance does not require the removal of radiator cap. Cooling system freeze protection should be tested at the onset of the winter season or every 12 months.

Service is required if coolant is low, contaminated, rusty or freeze protec- Fig. Mtion is inadequate. To properly test cooling system, see Group 7, Cooling System.

Using a suit- able hydrometer, measure antifreeze concentration in the radiator when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrom- eter reading. A mix table on the coolant container indicates the amount of antifreeze required to winterize the cooling system based on the capacity, see Capacity Chart in General Information section of this group.

Inspect and test radiator cap when cooling system service is performed or when problem is suspected. Refer to General Information section of this group. For proper service instructions see Group 7, Cooling System. Inspect all air cleaner hoses or tubes for damage or leaks when other engine compartment service is performed.

Replace faulty components. Do not immerse paper air filter element or tempera- ture sensor in cleaning solvents, damage can result. Hold a shop light on throttle body side of element. Inspect air intake side of element. If light is visible through element, blow dust from element Fig. If element is saturated with oil or light is not visible, replace filter.

If element is satu- rated with oil, perform crankcase ventilation system tests. If a metallic mesh is used to retain fiber filter, clean mesh with solvent and reuse. If oily, wash with solvent. To Install, reverse the preceding operation. The PCV system con- sists of a crankcase filter Figs. The PCV system should have enough volume to overcome crankcase pressure created by piston back- wash. If a PCV system becomes plugged, the crankcase pressure will increase and force engine oil past the piston rings creating oil consumption.

Chrysler Corporation recommends that a PCV valve not be cleaned. Over a period of time, depending on the environment where vehicle is used, deposits build up in the PCV vacuum circuit.

PCV system should be inspected at every oil change. Service PCV system if engine oil is discharged into air cleaner. Position a Fig. The card should be drawn to the end of the inlet hose within 15 seconds. If not, a leak or restriction exists in the PCV vacuum circuit. Vacuum hissing sound should be heard and engine should run steady.

Place a finger over end of PCV valve Fig. The engine should run very erratically or stall. If not, a vacuum restriction or blockage exists at the vacuum source. Use high quality, unleaded gasoline to provide satisfactory driveability and highest fuel economy.

Gasoline con- taining detergent and corrosion control additives are desireable. If the engine develops spark knock audible ping , poor performance, hard starting or stalling, purchase fuel from another source. Engine perfor- mance can vary when using different brands of gaso- line with the same octane rating. Occasional light engine spark knock under heavy acceleration, at low speed or when vehicle is heavily loaded is not harmful.

Extended periods of spark knock under moderate ac- celeration or at cruising speed can damage the engine. The cause of excessive spark knock condition must be diagnosed and corrected. Do not use leaded gasoline, damage to catalytic converter will result and vehicle will not conform to emission control standards. Higher octane premium unleaded gasoline can be used if desired. These fuels contribute less emissions to the atmosphere. Deterioration of fuel system components will result.

Methanol induced problems are not the responsibility of Chrysler Corpo- ration and may not be covered by the vehicle warranty. Oil and grime should be cleaned from the ignition cables and dis- tributor cap to avoid possible spark plug fouling. For proper service and diagnostic procedures refer to Group 8D, Ignition System. Refer to the General Information section of this group. For proper service procedures refer to Group 8D, Ignition Systems.

For proper inspection and adjustment procedures, see Group 7, Cooling System. Refer to emission system Vacuum Hose Label located on the inside of the hood in the engine compartment and Group 25, Emission Control Systems for proper service procedures.

Position plastic or rubber components away from moving parts in engine compartment or under ve- hicle, or damage will result. Do not allow rubber engine mounts or other com- ponents to become oil contaminated, repair cause of oil contamination and clean area. All rubber and plastic components should be in- spected when engine compartment or under vehicle service is performed. When evidence of deterioration exists, replacement is required.

Slight cracking in rubber isolator or hanger is accept- able. Severely cracked or broken rubber components must be replaced. For proper lubrication and service proce- dures refer to Group 6, Clutch, or Group 21, Manual Transaxle. To inspect the transaxle oil level, position the vehicle on a level surface. Remove fill plug Fig.

The manul transaxle does not require periodic main- tenance. The oil should be changed only when water contamination is suspected. If oil has a foamy or milky appearance it probably is contamined.

A circular mag- net located behind the differential cover collects metal- lic particles circulating in the oil. For proper diagnostic and service procedures, refer to Group 21, Manual Transaxle. For additional information, refer to Group 21, Transaxle. The warmer the transaxle fluid, the more accurate the reading.

Return gear selec- tor to park. If the vehicle has been driven for at least 15 minutes before inspecting fluid level, transaxle can be considered hot and reading should be above the WARM mark.

If vehicle has run for less than 15 minutes and more than 60 seconds Fig. Add fluid only if level is below ADD mark on dipstick when transaxle is warm. The automatic transaxle does not require periodic maintenance when used for general transportation. For additional information, refer to Severe Service para- graph and Lubrication and Maintenance Schedules in General Information section of this group. The fluid and filter should be changed when water contamina- tion is suspected.

If fluid has foamy or milky appear- ance, it is probably contaminated. If the fluid appears brown or dark and a foul odor is apparent, the fluid is burned, transaxle requires maintenance or service. A circular magnet located in the transaxle pan, collects metallic particles circulating in the oil. For proper diagnostic and service procedures, refer to Group 21, Automatic Transaxle.

To inspect the power transfer unit oil level, position the vehicle on a level surface and remove the fill plug Fig.

The oil level should be at the bottom edge of oil fill opening. The power transfer unit does not require periodic maintenance when subjected to normal driving condi- tions. The oil should be changed when water contami- nation is suspected. If oil has foamy or milky appear- ance it probably is contaminated. If the vehicle is subjected to severe driving conditions, the power trans- fer unit would require periodic maintenance every 29 km 12, miles.

Refer to Severe Service para- graph in General Information of this group for defini- tion of severe service. A magnet located in the unit to collect metallic particles circulating in the oil.

To inspect the overrunning clutch oil level, position the vehicle on a level surface and remove the fill plug Fig. The overrunning clutch does not require periodic maintenance when subjected to normal driving condi- tions. If the vehi- Fig. Refer to Severe Service paragraph in General Information of this group for definition of severe service.

For proper diagnostic and service procedures, refer to Group 3, Rear Suspension and Driveline. To inspect the power transfer unit oil level, position the vehicle on a level surface and remove fill plug Fig. The drive line module does not require periodic maintenance when subjected to normal driving condi- tions.

If the vehicle is subjected to severe driving conditions, the drive line module would require periodic maintenance every 36 km 22, miles. Inspect boots for cracking, tears, leaks or other defects. If service repair is required, refer to Group 2, Suspension. For proper diagnostic and service procedures refer to Group 2, Suspension.

The tires should be rotated at the distance intervals described in the Lubrication and Maintenance Schedules of the General Information section in this group. A Tire Inflation sticker is located in the driver door opening.

For proper diagnostic procedures, see Group 22, Wheels and Tires. Other rotation methods can be used, but may not have the benefits of the recommended method. Only the four tire rotation method can be used if the vehicle is equipped with a space saver spare tire. The rack and pinion steering gear end boots should not have excess oil or grease residue on the outside surfaces or surrounding areas Fig.

If boot is leaking, it should be repaired. For proper service procedures, see Group 19, Steering. The tie rod end seal should fit securely between the steering knuckle and tie rod end Fig.

The steering linkage should be lubricated at the time and distance intervals described in the Lubrication and Mainte- nance Schedules.

Using a wiping cloth, clean grease and dirt from around grease fitting and joint seal. Using a grease gun, fill tie rod end until lubricant leaks from around the tie rod end side of the seal Fig. When lube operation is complete, wipe off excess grease. The ball joint seal should fit securely between the steering knuckle and lower control arm Fig.

The ball joints should be lubri- cated at the time and distance intervals described in the Lubrication and Maintenance Schedules. Using a grease gun, fill ball joint until seal starts to swell Fig.

The power steering sys- tem should be inspected for leaks when Fig. For proper service procedures, refer to Group 19, Steering. The power steering pump drive belt should be in- spected at the time and distance interval described in the Lubrication and Maintenance Schedules.

Holding handle or cap above tip of dipstick, read fluid level Fig. Add fluid if reading is below cold level mark on dipstick. The bear- ings should be inspected for contamination and wear before they are cleaned.

Slight discoloration of bearing rollers and race cup is normal. If metal flakes are visible in the used lubricant or the bearing rollers and race cup is discolored, the bearing and race cup should be replaced. For proper service procedures, see Group 5, Brakes. Replace the inner seal whenever the wheel bearings are serviced.

Wash used or new bearings with a suitable solvent and blot dry with a lint free cloth before packing with new lubricant. Refer to Hoisting Recommen- dations in the General Information section of this group. For proper procedure, see Group 5, Brakes. For proper service procedure, see Group 5, Brakes.

Wash used lubricant from bearings with solvent and blot or blow dry. With a finger, smooth out grease around the outside of bearing. Loosen spindle nut one quarter turn. Hand tighten spindle nut. Refer to the General Informa- tion section of this group. If brake pads or linings appear excessively worn, the brakes would require service. For proper service procedures, refer to Group 5, Brakes. The front wheel, rear axle and anti-lock unit if equipped brake hoses should be inspected at time Fig.

A hose must be replaced if it has signs of cracking, chafing, fatigue or bulging. If a line is pinched, kinked, or corroded, it should be repaired.

The brake reservoir level should be inspected when other under hood service is performed. It is normal for the reservoir level to drop as disc brake pads wear. To avoid brake fluid contamination, use fluid from a properly sealed container. On vehicles with anti-lock brakes, depressurize the system before inspecting fluid level.

Turn OFF the ignition and remove the key. Pump the brake pedal at least 50 times to relieve the pressure in the system. On all vehicles, if fluid should become low after several thousand kilometers miles , fill the reservoir to level marks on the side of the reservoir Fig.

When luggage compartment is heavily loaded, the headlamp aim should be adjusted to compensate for vehicle height change. For proper service procedures, refer to Group 8L, Lamps. If the AIRBAG indicator lamp does not light at all, stays lit or lights momentarily or continuously while driving, a malfunction may have occurred.

Prompt service is required. Refer to Group 8M, Restraint Systems for proper diagnostic procedures. The airbag system and components should be in- spected and tested for electronic diagnostic fault codes at the intervals described in the Lubrication and Main- tenance Schedules in the Introduction section of this group.

Before a component is lubricated, oil, grease and dirt should be wiped off. If necessary, use solvent to clean component to be lubricated. After lubrication is Fig. To assure proper hood latching component operation, use engine oil to lubricate the latch, safety catch and hood hinges when other under hood service is per- formed.

A chart showing the breakdown of these designations is included in the Introduction section at the front of this Service Manual. An independent MacPherson Type front suspension is used on these vehicles. Vertical shock absorbing struts attach to the upper fender reinforcement and the steering knuckle to provide upper steering knuckle position.

Lower control arms are attached inboard to a crossmember and outboard to the steering knuckle through a ball joint to provide lower steering knuckle position. During steering maneuvers, the strut through a pivot bearing in the upper retainer and the steering knuckle turn as an assembly Fig.

The springs are contained between an upper seat, located just below the top strut mount assembly Fig. The top of each strut assembly is bolted to the upper fender reinforcement shock tower through a rubber isolated mount. The bottom attaches to the top of the steering knuckle with two through bolts.

On some vehicles, one bolt has an eccentric cam located below the head of the bolt for camber adjustment. On the other vehicles the camber adjustment is done by manually moving the steering knuckle within the strut assembly. Caster is a fixed setting on all vehicles and is not adjustable. The knuckle also holds the front drive hub bearing. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. The lower control arm is bolted to the crossmember with pivot bolts through the center of the rubber pivot bushings.