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Dodge Caravan CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Dodge REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Dodge Caravan car and truck
repair procedures including Dodge engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Dodge Caravan automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Dodge Caravan AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Dodge Caravan cars and light trucks from 1990+
Component Replacement & Adjustment -> Light Trucks & Vans Except Ram 50 -> Heater Core, Replace -> Auxiliary Heater Core -> Cherokee & Comanche -> D & W Pickups & Ramcharger -> Dakota -> Front Wheel Drive Van Models -> Grand Cherokee -> Less Air Conditioning -> Rear Wheel Drive Van Models -> Underdash Heater Core -> With Air Conditioning -> With Air Conditioning or Bi-Level Heater -> Wrangler
Vehicle: 1993 Dodge Caravan ES 3.0 V6 GAS
D & W Pickups & Ramcharger
Less Air Conditioning
- Disconnect battery ground cable.
- Disconnect heater hoses on engine side and plug heater outlets.
- Remove right side cowl trim if so equipped.
- Remove glove box, then structural brace through glove box opening.
- Remove right half of instrument panel lower reinforcement, making sure to disconnect ground strap.
- Disconnect control cables, then blower motor wires on engine side.
- Disconnect wires from resistor block, Fig. .
- Remove screw holding heater to cowl side sheet met...
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BRAKE SERVICE PROCEDURES FOR Dodge Caravan AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Dodge Caravan cars and light trucks from 1990+.
DRUM BRAKES, CHRYSLER CORP. -> Drum Brakes, Chrylser -> PARKING BRAKE, Adjust -> FRONT WHEEL DRIVE MODELS -> RAM 50 -> RAM RAIDER -> REAR WHEEL DRIVE EXCEPT RAM RAIDER & RAM 50
Vehicle: 1990 Dodge Caravan C/V 3.0 V6 GAS
FRONT WHEEL DRIVE MODELS
- Raise and support vehicle.
- Release parking brake and back off cable adjustment to slacken cable.
- Tighten cable adjusting nut until a slight drag is obtained while rotating wheels.
- Loosen cable adjusting nut until rear wheels rotate freely, then an additional two turns.
- Apply and release parking brake to check for proper operation. The rear wheels should rotate without dragging.
REAR WHEEL DRIVE EXCEPT RAM RAIDER & RAM 50
- Release parking brake lever and loosen cable adjusting nut to be sure cable is slack.
- With rear wheel brakes properly adjusted tighten ca...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Dodge Caravan AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Dodge Caravan cars and light trucks sold in the U.S. for 1980+.
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Caravan, Town & Country & Voyager w/2001-06 2.4L, 3.3L & 3.8L Engines, 1996-00 3.0L Engine
Vehicle: 2003 Dodge Caravan SE 3.3 V6 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reco...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Dodge Caravan AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Dodge Caravan cars and light trucks from 1990+.
CV AXLE SHAFT, Replace -> Front -> Rear
Vehicle: 1996 Dodge Caravan SE 3.3 V6 GAS
Front
- Remove cotter pin, nut lock, and spring washer from end of outer CV joint stub axle.
- Loosen (but do not remove) stub axle to hub/bearing retaining nut. Loosen hub nut while vehicle is on the floor with brakes applied. Front hub and driveshaft are splined together and retained by hub nut.
- Raise vehicle on jack stands or centered on a frame contact type hoist.
- Remove front tire and wheel assembly from hub.
- Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts.
- Remove disc brake caliper assembly from steering knuckle. Caliper is removed by fi...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Dodge Caravan AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Dodge Caravan cars and light trucks sold in the U.S. from mid 1990's+.
Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification -> Intermittent & Poor Connections -> Intermittents -> Poor Connections -> Tire Pressure Sensor
Vehicle: 2005 Dodge Caravan 3.3 V6 GAS
Tire Pressure Sensor
Tire pressure may increase from 2-6 psi during normal driving conditions. Do not reduce this normal pressure build-up.
When diagnosing a tire pressure issue, always inspect air pressure in the tires first with suitable tire air gauge. Adjust air pressure as required to specifications listed on the Tire Inflation Pressure Label card, usually applied within driver side B-pillar. After adjusting air pressure in tire on vehicle, allow approximately two minutes for the message or indicator lamp to go out.
Inspect tire pressure indicator lamp in the instrument cl...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Dodge Caravan AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Dodge Caravan cars and light trucks from 1990+.
Starter, Replace
Vehicle: 1998 Dodge Caravan 3.3 V6 GAS
- Remove battery ground cable.
- Raise and support vehicle.
- Remove nut and lockwasher securing starter motor to mounting stud on manual transmission clutch housing or automatic transmission torque converter housing.
- While supporting starter with one hand, remove upper mounting screw from starter.
- On models equipped with automatic transmission,slide transmission cooler tube bracket forward on tubes far enough for starter motor flange to be removed from lower mounting stud.
- On all models, move starter motor towards front of vehicle...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Dodge Caravan AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Dodge Caravan cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Chrysler LLC -> 2000-07 Caravan, Grand Caravan, Grand Voyager, Town & Country, Voyager & 2004-08 Pacifica
Vehicle: 2005 Dodge Caravan 3.3 V6 GAS
On 2000-03 models, the cabin air filter should be replaced every 15,000 miles.
On 2004-08 models, the cabin air filter should be replaced every 12,000 miles.
- The cabin air filter is located under the passenger side of the instrument panel behind a cabin air filter access door on the lower evaporator housing.
- Slide the cabin air filter access door latch rearward until the latch engages the open stop, Fig. .
- Remove the cabin air filter acc...
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MAINTENANCE LAMP RESET PROCEDURES FOR Dodge Caravan AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Dodge Caravan cars and light trucks sold in the U.S. from 1990+.
Chrysler LLC Trucks -> Emission Maintenance Reminder Indicator -> Chrysler, Dodge & Plymouth
Vehicle: 1990 Dodge Caravan LE 3.0 V6 GAS
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Dodge Caravan AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Dodge Caravan cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Dodge Caravan LE 2.5 L4 GAS
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SERPENTINE BELT SERVICE PROCEDURES FOR Dodge Caravan AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Dodge Caravan cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace -> Alternator & Air Conditioner Compressor -> Power Steering Pump
Vehicle: 1996 Dodge Caravan SE 2.4 L4 GAS
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COMPONENT LOCATION DIAGRAMS FOR Dodge Caravan AUTOMOBILES
Component location diagrams for most Dodge Caravan cars and light trucks sold in the U.S. from 1990+.
 Instrument Panel Splices Diagram for 1994 Dodge Caravan SE 3.3 V6 CNGComponents on diagram: |
 Door Splice Locations Diagram for 2001 Dodge Caravan SE 3.3 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Dodge Caravan AUTOMOBILES
OEM drawn wiring diagrams for most Dodge Caravan cars and light trucks sold in the U.S.
 2006 Dodge Caravan 3.3 V6 GAS Wiring DiagramComponents on diagram: |
 1995 Dodge Caravan ES 3.3 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Dodge Caravan AUTOMOBILES
OEM TSB listings for most Dodge Caravan cars and light trucks sold in the U.S. from 1985+.
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Document: ABS - PEDAL DOESN'T FULLY RELEASE/STOPLAMPS STAY LIT Vehicle: 1990 Dodge Caravan 2.5 L4 GAS Auto Systems: |
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Document: RECORDABLE COMPACT DISCS USED IN CD PLAYERS Vehicle: 1999 Dodge Caravan 3.3 V6 FLEX Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Dodge Caravan AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Dodge Caravan cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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