1991 Dodge Caravan Service and Repair Manual

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Factory-Grade Data

1991 Dodge Caravan service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • C/V Mini Cargo Van 3-Door
  • SE Mini Passenger Van 3-Door
  • LE Mini Passenger Van 3-Door
  • ES Mini Passenger Van 3-Door
  • Base Mini Passenger Van 3-Door

Engines covered

  • 2.5L 2507CC 153Cu. In. l4 GAS SOHC Naturally Aspirated
  • 3.0L 2972CC 181Cu. In. V6 GAS SOHC Naturally Aspirated
  • 3.3L 3301CC 201Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Dodge Caravan Recalls & Complaints

NHTSA #95I00100627/03/1995Component: LATCHES/LOCKS/LINKAGES:HATCHBACK/LIFTGATE:LOCK

VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITH REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER

Consequence

IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF I

Remedy

CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE.

NHTSA #95I00100227/03/1995Component: LATCHES/LOCKS/LINKAGES:HATCHBACK/LIFTGATE:LOCK

VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITHOUT REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYS

Consequence

IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF I

Remedy

CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE.

NHTSA #96V22900018/11/1996Component: STEERING: STEERING WHEEL/HANDLE BAR

THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.

Consequence

IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTR

Remedy

DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY

NHTSA #99V18900016/07/1999Component: VISIBILITY:WINDSHIELD WIPER/WASHER:LINKAGES

VEHICLE DESCRIPTION: MINIVANS. THE LEFT HAND WINDSHIELD WIPER PIVOT DRIVE ARM WAS NOT MECHANICALLY STAKED TO THE PIVOT SHAFT.

Consequence

THIS COULD ALLOW THE DRIVE ARM TO DISENGAGE FROM THE SHAFT LEADING TO A LOSS OF WIPER FUNCTION. THE

Remedy

DEALERS WILL REPLACE THE LEFT HAND SIDE WINDSHIELD WIPER PIVOT ASSEMBLY.

NHTSA #96V09900013/06/1996Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED

THE ABS HYDRAULIC CONTROL UNIT CAN EXPERIENCE EXCESSIVE BRAKE ACTUATOR PISTON SEAL WEAR CAUSING PUMP-MOTOR DETERIORATION.

Consequence

IF THIS CONDITION OCCURS, THE ABS FUNCTION COULD BE LOST AND REDUCED POWER ASSIST WOULD BE EXPERIENC

Remedy

DEALERS WILL TEST THE VEHICLE'S ANTI-LOCK BRAKE SYSTEM AND REPAIR THE VEHICLES IF NECESSARY. ALSO TH

NHTSA #91V04100011/03/1991Component: EXTERIOR LIGHTING:TURN SIGNAL:FLASHER UNIT

INCORRECT TURN SIGNAL FLASHER INHIBITS INDICATION OF SIGNAL LAMP OUTAGE.

Consequence

INOPERATIVE TURN SIGNAL LAMPS WOULD NOT INFORM DRIVERTHAT A LAMP WAS OUT, OR WARN OTHER DRIVERS OF I

Remedy

REPLACE TURN SIGNAL FLASHER WITH PROPER FLASHER.

NHTSA #92V03000010/03/1992Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, A

THE ANTI-LOCK BRAKE SYSTEM HIGH PRESSURE PUMP MAY BE POROUS WHICH WILL RESULT IN BRAKE FLUID LEAKAGE.

Consequence

FLUID LEAKAGE EVENTUALLY CAUSES THE LOSS OF BOTH THEANTI-LOCK BRAKE SYSTEM AND HYDRAULIC ASSIST FOR

Remedy

REPLACE THE ABS HIGH PRESSURE PUMP AND HIGH PRESSURE HOSE IF THE LAST SIX DIGITS OF THE BAR CODE LAB

NHTSA #97V14900009/09/1997Component: SEAT BELTS:FRONT:ANCHORAGE

VEHICLE DESCRIPTION: PASSENGER MINI-VANS. THE CENTER REAR SEAT, RIGHT OUTBOARD SIDE, SAFETY BELT ANCHOR HOOK CAN BECOME UNATTACHED FROM THE BODY ANCHOR POSITION.

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF

Remedy

DEALERS WILL REPLACE THE ANCHOR HOOK RETAINING CLIP WITH A REVISED PROFILE CLIP AND A COVER PLATE.

NHTSA #97V14800009/09/1997Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLY

VEHICLE DESCRIPTION: PASSENGER MINI-VANS. COVERS ON THE SOLID STALK MOUNTED SEAT BELT BUCKLES CAN BECOME DISLODGED CAUSING THE RELEASE BUTTON TO STICK INSIDE THE COVER. THE BUCKLE WOULD THEN BE ONL

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF

Remedy

DEALERS WILL INSTALL A COVER RETAINING CLIP TO THE STALK MOUNTED BUCKLE COVER TO PREVENT DISLOCATION

NHTSA #99V21300002/09/1999Component: STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS

VEHICLE DESCRIPTION: MINI VANS. THE BOLTS USED TO ATTACH THE STRUT TO THE BODY AND THE REAR LIFTGATE CAN ACCUMULATE FATIGUE DAMAGE IF THREE FACTORS COMBINE. IF THE BOLT IS LOOSE, THE GAS STRUT IS O

Consequence

PERSONAL INJURY COULD OCCUR IF THE BOLTS BREAK ALLOWING THE LIFTGATE TO FALL SUDDENLY.

Remedy

DEALERS WILL INSPECT FOR LOOSE FASTENERS, IF THE FASTENERS ARE LOOSE, THE STRUT (AND INTEGRAL BOLTS)

NHTSA #91V19100001/11/1991Component: SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, A

THE ANTI-LOCK BRAKE SYSTEM HIGH PRESSURE HOSE MAY LEAK OR DETACH AT ITS CRIMPED END FITTING RESULTING IN THE DISCHARGE OF HYDRAULIC FLUID.

Consequence

FLUID DISCHARGE EVENTUALLY CAUSES THE LOSS OF BOTH THEANTI-LOCK BRAKE SYSTEM AND HYDRAULIC ASSIST FO

Remedy

REPLACE THE ABS HIGH PRESSURE HOSE WITH A HOSE OF DIFFERENT DESIGN AND CONSTRUCTION.

TSB #620059

SUBJECT REGARDING AIRBAG / CLOCK SPRING SERVICE FOR VARIOUS MODELS INCLUDING 2002 MODEL YEAR JEEP LIBERTY. *TT

TSB #618049

SUBJECT REGARDING WIRE SPLICE REPAIRS. *SB

TSB #615688

SUBJECT REGARDING CHILD SEAT TETHER ANCHORS. *TT

TSB #6092304

SUBJECT REGARDING NON-DEPLOYED AIRBAG HANDLING PROCEDURES. *TT

TSB #612160

SUBJECT ON THE CHILD SEAT TETHER ANCHORS. *MJS

TSB #610635

SUBJECT REGARDING CHILD SEAT TETHER ANCHORS. *TT

TSB #609995

THIS BULLETIN PROVIDES A REVISED WIRE SPLICE PROCEDURE AND RELATED PARTS. *TT

TSB #6089800

DAIMLERCHRYSLER CORPORATION IS NOW OFFERINB AIRBAG ON / OFF SWITCHES FOR SELECTED VEHICLES. *TT

Showing the 8 most recent of 40 technical service bulletins on file with NHTSA.

19980518Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported3 injured

WHILE DRIVING ON FREEWAY AT 65MPH, WHEN APPLYING BRAKES, REAR WHEELS LOCKED, VAN WENT OUT OF CONTROL, FLIPPED THREE TIMES, THE PAVEMENT WAS DAMP, NO RAIN, RESULTED IN THREE INJURIES, THE DEALER WHERE

19950613Component: STRUCTURE:FRAME AND MEMBERSCrash reported3 injured

IN ACCIDENT AFTER ROLLING OVER 6 TIMES THE REAR HATCH OPENED AND 2 CHILDREN EJECTED 1 CHILD WAS CAUGHT IN DOOR RECIEVING SERIOUS INJURIES. TT

19950613Component: STRUCTURE:BODY:HATCHBACK/LIFTGATECrash reported3 injured

IN ACCIDENT AFTER ROLLING OVER 6 TIMES THE REAR HATCH OPENED AND 2 CHILDREN EJECTED 1 CHILD WAS CAUGHT IN DOOR RECIEVING SERIOUS INJURIES. TT

19980421Component: AIR BAGS:FRONTAL:SENSOR/CONTROL MODULECrash reported2 injured

AIR BAG RELAY ON THE LEFT FRONT, CRACKED ON BOTH SIDES OF THE BOLTS THAT CONNECT IT TO THE FRAME DURING A COLLISION, RESULTING IN INJURIES. VEHICLE ALSO SUSTAINED EXCESSIVE DAMAGE.

19950407Component: STRUCTURE:BODY:HATCHBACK/LIFTGATECrash reported2 injured

REAR DOOR OPENED UPON A REAR COLLISION. TT

Showing the 5 most serious of 773 complaints filed with NHTSA.

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