1987 Dodge Caravan Repair Manual

The 1987 Dodge Caravan Repair Manual provides comprehensive guidance for maintaining and repairing the first-generation minivan featuring front-wheel drive, 2.2L or 2.6L engine options, 3-speed automatic or 5-speed manual transmission, and versatile seating configurations. This manual covers engine systems, transmission, brakes, suspension, electrical, heating/cooling, and body components with detailed procedures, specifications, and troubleshooting guides.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Repair 4. Transmission Service 5. Brake System 6. Suspension & Steering 7. Electrical System 8. Heating & AC 9. Body & Interior 10. Troubleshooting Guide 11. Wiring Diagrams

Vehicle Specifications

Key specifications for the 1987 Dodge Caravan including engine options, dimensions, and capacities.

Specification	Details
Engine Options	2.2L I4 (97 hp), 2.6L I4 (104 hp)
Transmission	3-speed automatic, 5-speed manual
Drivetrain	Front-wheel drive
Wheelbase	112.0 inches
Length	175.9 inches
Curb Weight	2,800-3,100 lbs
Fuel Capacity	15.0 gallons
Oil Capacity	4.0 quarts (2.2L), 4.5 quarts (2.6L)
Coolant Capacity	9.5 quarts
Tire Size	P195/75R14

Maintenance Schedule

Recommended maintenance intervals for optimal vehicle performance and longevity.

Oil Change: Every 3,000 miles or 3 months
Oil Filter: Replace with every oil change
Air Filter: Inspect every 12,000 miles, replace as needed
Spark Plugs: Replace every 30,000 miles
Timing Belt: Replace every 60,000 miles (2.6L engine)
Coolant Flush: Every 30,000 miles or 2 years
Brake Fluid: Replace every 30,000 miles or 2 years
Transmission Fluid: Every 15,000 miles (automatic), 30,000 miles (manual)

WARNING! Always use jack stands when working under vehicle. Disconnect battery before electrical work.

Engine Repair

Procedures for common engine repairs and component replacement.

Spark Plug Replacement: Remove ignition wires, use 13/16" socket, gap to 0.035"
Valve Adjustment: Cold engine only, intake 0.008", exhaust 0.010"
Timing Belt: Align marks, tension properly, replace idler pulley
Water Pump: Drain coolant, remove drive belts, install new gasket
Oil Pan: Remove crossmember for access, clean sealing surfaces
Cylinder Head: Torque bolts in sequence to 70 ft-lbs

CAUTION! Allow engine to cool before working. Use proper torque specifications.

Transmission Service

Automatic Transmission: A413 model, fluid capacity 7.5 quarts
Manual Transmission: Cable-operated clutch, fluid capacity 2.1 quarts
Fluid Type: ATF+3 for automatic, 75W-90 gear oil for manual
Shift Linkage: Adjust for proper gear engagement
Clutch Replacement: Remove transmission, replace pressure plate and disc
Differential: Integrated with transaxle, service with transmission

Brake System

Front disc brakes, rear drum brakes with power assist.

Front Brakes: 10.2" rotors, single piston calipers, pad thickness minimum 1/8"

Rear Brakes: 9.0" drums, self-adjusting mechanism, shoe thickness minimum 1/16"

Bleeding Procedure: Start with right rear, left rear, right front, left front. Master Cylinder: Bench bleed before installation. Parking Brake: Cable adjustment under vehicle.

Suspension & Steering

Front: MacPherson struts, lower control arms. Rear: Beam axle with leaf springs.

Strut Replacement: Support vehicle, remove knuckle bolts, compress spring safely
Ball Joints: Check for play, replace if movement exceeds 1/8"
Tie Rod Ends: Count threads for alignment, replace if boot torn
Wheel Bearings: Pack with grease, adjust preload properly
Alignment Specs: Camber -0.5° to +0.5°, Toe 0° to +0.20°

Tip: Mark alignment camber bolts before removal for easier reassembly.

Electrical System

12-volt negative ground system with 60-amp alternator.

Battery: Group 24, 450 CCA, clean terminals regularly
Alternator: Output test - 13.5-14.5 volts at 2000 RPM
Starter: Draw test - 150-200 amps maximum
Fuses: 10-amp to 30-amp in under-dash panel
Headlights: Sealed beam type, adjust aim properly
Instrument Cluster: Remove bezel for bulb replacement
Wiring: Color-coded, repair with solder and heat shrink

WARNING! Disconnect battery before electrical repairs. Use circuit tester for diagnosis.

Heating & AC

R-12 refrigerant system, blend-air temperature control.

Body & Interior

Unibody construction, sliding side door, removable seats.

CAUTION! Use proper lifting points. Support doors when removing hinges.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery, ignition, fuel	Check battery voltage, spark at plugs, fuel pressure
Overheating	Coolant, thermostat, fan	Check coolant level, test thermostat, verify fan operation
Brake pull	Calipers, alignment	Inspect calipers for sticking, check front end alignment
Transmission slip	Fluid, bands	Check fluid level and condition, adjust bands if applicable
Electrical issues	Grounds, alternator	Clean battery grounds, test alternator output

Reset: Disconnect battery for 30 minutes to reset computer.

Service: Refer to Dodge dealership or certified mechanic for complex issues.

Wiring Diagrams

Complete electrical schematics for engine management, lighting, and accessory systems. Diagrams show wire colors, connector locations, and circuit protection devices. Use with multimeter for accurate diagnosis of electrical faults.