Maintenance Information Dodge Caravan I

MODEL IDENTIFICATION

Note. For scheduled maintenance intervals and the related fluid capacities, fluid specifications and labor times for major service intervals, see SCHEDULED SERVICES article below

1. SCHEDULED SERVICES
2. SCHEDULED SERVICES - TURBO (1989-90)

Warranty information and specifications for fluid capacities, lubrication specifications, wheel and tire size, and battery type are covered in this article.

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 3

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Severe Service

1. Sustained High Speed Driving In Hot Weather
2. Stop-And-Go Driving In Dusty Conditions
3. Extensive Idling
4. Frequent Short Trips
5. Trailer Towing Or Commercial Use

Normal Service

1. Driven More Than 10 Miles Daily
2. No Severe Service Operating Conditions

CAMSHAFT TIMING BELT

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist

1. Cracks Or Tears In Belt Surface
2. Missing, Damaged, Cracked Or Rounded Teeth
3. Oil Contamination
4. Damaged Or Faulty Tensioners
5. Incorrect Tension Adjustment

Scheme 4

Scheme 5

Scheme 6

Scheme 7

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

TIRE INFLATION

Tire pressure is listed on a certification label attached to vehicle's left front door.

WHEEL TIGHTENING

Tighten all wheel lug nuts to 95 ft. lbs. (129 N.m).

BATTERY SPECIFICATIONS

All models use group 34 batteries with a cold crank rating of 600 amps.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

REPLACING BLOWN FUSES

BATTERY WARNING

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

FUEL SYSTEM SERVICE

HALOGEN BULBS

METHANOL GASOLINE

RADIATOR CAP

RADIATOR FAN

SPARK PLUGS

Note. Allow engine to cool before removing spark plugs from aluminum cylinder heads.

TIRE SEALANTS

TURBOCHARGED MODELS

WARRANTY INFORMATION

BASIC NEW CAR LIMITED WARRANTY (1984-94)

Everything is covered for 12 months or 12,000 miles, whichever occurs first. Warranty covers repairs to any vehicle components (tires excluded), which have proven defective in material and workmanship in normal use. Warranty repairs (parts and labor) will be made by the dealer at no charge using new or remanufactured parts.

POWERTRAIN WARRANTY

Upon expiration of the 12-month/12,000-mile Basic New Car Limited Warranty, the powertrain warranty covers components listed below for 7 years or 70,000 miles. This warranty is subject to a 100 deductible for each repair visit. The warranty also covers cost of towing to the nearest Chrysler dealer if vehicle can't be driven due to failure of a covered powertrain part.

1. Engine Cylinder block and all internal parts, seals and gaskets.
2. Transmission Transmission case and all internal parts, seals and gaskets, oil pan, torque converter with starter ring gear and flexplate, clutch housing and flywheel.
3. FWD Components Transaxle case and all internal parts, seals and gaskets, oil pan and differential cover, torque converter and drive plate with starter ring gear, clutch housing, flywheel and drive shaft assemblies
4. RWD Components Drive axle housing and all internal parts, seals and gaskets; axle shaft bearings and seals; drive shaft assemblies; universal joints and yokes.

AIR BAG LIMITED WARRANTY

Air bag system components listed below are covered for 36 months or 36,000 miles, whichever occurs first. There is no deductible cost.

1. Air Bag Module
2. Clockspring Switch Assembly
3. Front Impact Sensor
4. Air Bag System Diagnostic Module

CORROSION COVERAGE

Warranty starts on the date the vehicle is delivered or put in use, whichever occurs first and extends for 36 months regardless of mileage. Outer body panels are covered for 7 years or 100,000 miles, whichever occurs first. Covers any rust-through in body sheet metal due to corrosion.

EMISSION SYS "DEFECT" & "PERFORMANCE" WARRANTIES (EXC CALIF)

Under the Defect Warranty, Chrysler warrants that the vehicle is free from defects in material and workmanship which would cause it to fail to meet Federal standards for emission control system set at the time the vehicle was built.

The Performance Warranty covers all costs of repairing or adjusting any components or parts as needed in order for the vehicle to pass a Federally-approved state or local emissions test. The following is a list of some of the primary components that affect the emissions of the vehicle and are covered by both warranties.

Other emission control parts related to these components are covered by the Performance warranty, where applicable. If another part fails due to the failure of one of these components, both parts are covered. Warranties begin on warranty start date and last for 5 years or 50,000 miles, whichever occurs first.

1. Electronic Fuel Injection System
2. Air Cleaner Vapor Containment Door System
3. Electronic Spark Control
4. Electronic Control Module
5. Vapor Storage Canister And Controls
6. Deceleration Throttle Control
7. Exhaust Gas Recirculation Valve And Control System
8. Air Pump, Belt And Pulley
9. Air Injection Controls
10. Intake Manifold
11. PCV Valve
12. Catalytic Converter
13. Vacuum Hoses, Clamps, Fittings And Tubing
14. Vacuum, Temperature, Altitude, Speed And Time-Sensitive Valves

Note. Some of these parts require scheduled replacement, as described in the vehicle's Owner's Manual. These parts are warranted only until the time they are first scheduled to be replaced.

EMISSION "PERFORMANCE" WARRANTY (CALIFORNIA)

If vehicle fails a Smog Check inspection, all necessary repairs and adjustments will be made by manufacturer to ensure that your vehicle passes the inspection. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.

EMISSION "DEFECT" WARRANTY (CALIFORNIA)

If any emission-related part on the vehicle is defective, the part will be repaired or replaced by manufacturer. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first. Some emission-related parts are warranted for 7 years or 70,000 miles whichever occurs first, and will be repaired or replaced by manufacturer if found to be defective in material or workmanship. See customer's copy of warranty information for specific items covered.

FUSES & CIRCUIT BREAKERS

Fuse panel is located under the parking brake handle on the left side of the steering column.

Scheme 8

Fuse & Relay Identification

1. 1 - 20 Amp - Hazard Flasher
2. 2 - 20 Amp - Back-Up Lights, A/C Fan & Clutch Relay Coil, Heater Rear Window Switch, Rear A/C, Rear Heater, Overhead Console (1984-87)
3. 3 - 30 Amp - Power Window Motors, Sun Roof (1984-87), Power Vent Windows (1984-87)
4. 4 - 30 Amp - A/C or Heater Blower Motor
5. 5 - 20 Amp - Taillights, Park, Side Marker & License Lights (1984-89), Clock, Radio, Overhead Console Intensity (1984-87), Rear A/C Unit Light (1988-89)
6. 6 - 20 Amp - Stoplights, Chimes
7. 7 - 25 Amp - Horns, Cigarette Lighter, Power Amp Feed, Horn Relay (1988-89)
8. 8 - 30 Amp - Power Seat Motors, Power Door Locks, Power Mirrors
9. 9 - 10 Amp - Radio & Clock Display
10. 10 - 20 Amp - Turn Signal Lights, Van Conversion Relay (1984-87)
11. 11 - 20 Amp - Windshield Washer/Wiper
12. 12 - 4 Amp - Cluster, A/C & Heater Controls, Ash Receiver, Radio, Overhead Console, Rear Heater Switch, A/C Switch Lights, Cigarette Lighter (1984-87), Headlight Switch (1984-87)
13. 13 - 5 Amp - Fuel, Voltage, Oil & Temp Gauges & Lights, BRAKE Warning, Liftgate Open (1984-87), Seat Belt Warning Module, Upshift (1984-87), CHECK ENGINE Lights, Speed Control, Fuel Pacer (1988-89)
14. 14 - 20 Amp - Rear Washer/Wiper & Liftgate Release, Electronic Module (Manual Transmission 1984-87)
15. 15 - 10 Amp - Under Seat Storage, Lower Console, Dome, Map, Cargo & Storage Lights, Ignition, Headlight, Courtesy, Vanity Mirror Lights, Radio Memory, Time Delay Relay (1988-89)
16. 16 - 25 Amp - Power Vent Windows (1984-87), Blank (1988-89)
17. 17 - Relay - Horn Relay
18. 18 - Relay - Ignition Switch, Key Light Time Delay Relay
19. 19 - Flasher - Turn Signal Flasher

FUSE PANEL IDENTIFICATION (1990 MODELS)

Note. Headlight circuit breaker is integral with switch assembly.

1. 1 - 20 Amp - Hazard Flasher
2. 2 - 20 Amp - Back-Up Lights, A/C Fan & Clutch Relay Coil, Heater Rear Window Switch
3. 3 - 30 Amp - Power Window Motors
4. 4 - 30 Amp - A/C Or Heater Blower Motor
5. 5 - 20 Amp - Taillights, Park, Side Marker & License Lights
6. 6 - 20 Amp - Stoplights, Dome, Cargo, Vanity Mirror, Ignition Switch Light, Electric Mirror, Time Delay Relay, Door Courtesy Lights
7. 7 - 25 Amp - Horns, Horn Relay, Cigarette Lighter, Buzzer Or Chimes, Radio Memory
8. 8 - 30 Amp - Power Seat Motors, Power Door Locks
9. 9 - 10 Amp - Radio & Clock Power
10. 10 - 20 Amp - Turn Signal Lights, Van Conversion Relay
11. 11 - 20 Amp - Windshield Washer/Wiper
12. 12 - 4 Amp - Cluster, A/C & Heater Controls, Ash Receiver, Radio
13. 13 - 5 Amp - Fuel Gauge, BRAKE Warning, Oil Gauge, Seat Belt Warning Buzzer, Temp Gauge, Speed Control, Oil & Temp Lights, Fuel Pacer
14. 14 - 20 Amp - Rear Washer/Wiper & Liftgate Release
15. 15 - 20 Amp - Spotlight (Fleet)
16. 16 - 20 Amp - Spotlight (Fleet)
17. 17 - Relay - Horn Relay
18. 18 - Relay - Ignition Switch, Key Light Time Delay Relay
19. 19 - Flasher - Turn Signal Flasher