brake DODGE CARAVAN 2009 Service Manual

6. Block both the front and rear of the
wheel diagonally opposite the jacking
position. For example, if changing the
right front tire, block the left rear
wheel.
NOTE:Passengers should not remain in the vehicle
when the vehicle is being jacked.
Jacking Instructions
WARNING!
Carefully follow these tire changing warnings to
help prevent personal injury or damage to your
vehicle:
(Continued)
WARNING! (Continued)
•Always park on a firm, level surface as far from
the edge of the roadway as possible before raising
the vehicle.
•Block the wheel diagonally opposite the wheel to
be raised.
•Set the parking brake firmly and set an automatic
transmission in PARK; a manual transmission in
REVERSE.
•Never start or run the engine with the vehicle on a
jack.
•Do not let anyone sit in the vehicle when it is on a
jack.
•Do not get under the vehicle when it is on a jack.
•Only use the jack in the positions indicated and
for lifting this vehicle during a tire change.
(Continued)
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WARNING! (Continued)
•Take special care to avoid the radiator cooling fan
whenever the hood is raised. The cooling fan is
electrically operated and can start anytime the
ignition switch is ON. You can be hurt by the fan.
•During cold weather when temperatures are be-
low the freezing point, electrolyte in a discharged
battery may freeze. Do not attempt jump-starting
because the battery could rupture or explode. The
battery temperature must be brought up above the
freezing point before attempting a jump-start.
When jump-starting, proceed as follows:
1. Wear eye protection and remove any metal jewelry,
such as watch bands or bracelets, that might make an
inadvertent electrical contact.2. When a boost is provided by a battery in another
vehicle, park that vehicle within booster cable reach and
do not let the vehicles touch. Set the parking brake, place
the automatic transmission shift lever into PARK and
turn the ignition switch to the OFF position for both
vehicles.
3. Turn OFF the heater, radio and all unnecessary elec-
trical loads.
4. Connect one end of a jumper cable to the positive
terminal of the discharged battery. Connect the other end
of the same cable to the positive terminal of the booster
battery.
WARNING!
Do not permit vehicles to touch each other, as this
could establish a ground connection and personal
injury could result.
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▫Windshield Wiper Blades............... 449
▫Cooling System...................... 450
▫Brakes............................ 456
▫Automatic Transaxle.................. 458
▫Appearance Care And Protection From
Corrosion.......................... 460
▫Cleaning The Instrument Panel Cupholders . . 466
Fuses.............................. 467
▫Totally Integrated Power Module (TIPM).... 467
Vehicle Storage....................... 474
Replacement Light Bulbs................. 474
Bulb Replacement..................... 475▫Headlights......................... 475
▫Front Park/Turn Signal Lights........... 476
▫Fog Lights......................... 476
▫Rear Tail, Stop, Turn Signal, Side Marker
And Backup Lights................... 477
▫Center High-Mounted Stop Light (CHMSL) . . 478
▫License Light....................... 478
Fluids And Capacities................... 479
Fluids, Lubricants And Genuine Parts....... 480
▫Engine............................ 480
▫Chassis............................ 481
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ENGINE COMPARTMENT — 3.3/3.8L
1 — Air Cleaner Filter 7 — Engine Oil Fill
2 — Automatic Transmission Dipstick (3.3L Only) 8 — Engine Oil Dipstick
3 — Brake Fluid Reservoir 9 — Coolant Pressure Cap
4 — Battery 10 — Washer Fluid Reservoir
5 — Totally Integrated Power Module 11 — Power Steering Fluid Reservoir
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ENGINE COMPARTMENT — 4.0L
1 — Power Steering Fluid Reservoir 7 — Engine Oil Dipstick
2 — Air Cleaner Filter 8 — Engine Oil Fill
3 — Brake Fluid Reservoir 9 — Coolant Pressure Cap
4 — Battery 10 — Washer Fluid Reservoir
5 — Totally Integrated Power Module
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•Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, also keep the front of
the condenser clean also.
•Do not change the thermostat for Summer or Winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.
Brakes
In order to assure brake system performance, all brake
system components should be inspected periodically.
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.
WARNING!
Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You wouldn’t have your full
braking capacity in an emergency.
Master Cylinder — Brake Fluid Level Check
The fluid level in the master cylinder should be checked
when performing underhood services, or immediately if
the brake system warning light indicates system failure.
Clean the top of the master cylinder area before removing
the cap. Add fluid to bring the level up to the top of the
“FULL” mark on the side of the master cylinder reservoir.
Overfilling of fluid is not recommended because it may
cause leaking in the system.
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Add enough fluid to bring the level up to the require-
ments described on the brake fluid reservoir. With disc
brakes, fluid level can be expected to fall as the brake
pads wear. However, low fluid level may be caused by a
leak and a checkup may be needed.
Use only manufacturer’s recommended brake fluid. Re-
fer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.
WARNING!
•Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
(Continued)
WARNING! (Continued)
•Use of a brake fluid that has a lower initial boiling
point than the recommended MOPARDOT 3
product or a brake fluid that is unidentified as to
FMVSS specification may result in sudden brake
failure during hard prolonged braking. You could
have an accident.
Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.
CAUTION!
Do not allow petroleum based fluid to contaminate
the brake fluid — all brake seal components could be
damaged, causing partial or complete brake failure.
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Fluid Level Check — 3.8L and 4.0L Engines with
Six-Speed Automatic Transaxle — If Equipped
The six-speed automatic transaxle is a sealed unit and has
no dipstick. See your authorized dealer to have the
transaxle fluid checked or serviced.
Fluid Level Check — 3.3L Engine with Four-Speed
Automatic Transaxle — If Equipped
The dipstick is located just behind the radiator on the
lower right side.
To properly check the automatic transaxle fluid level, the
following procedure must be used:1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for a
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector lever momentarily in each gear
position, ending with the lever in PARK. Wipe the area
around the dipstick clean to eliminate the possibility of
dirt entering the transaxle.
5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180°F (82°C), which
is the normal operating temperature after the vehicle has
been driven at least 15 miles (24 km). The fluid cannot be
comfortably held between the fingertips. Cold is when
the fluid is below 80°F (27°C).
6. Wipe the dipstick clean and reinsert until seated.
Remove dipstick and note reading.
4 Speed ATX Diptstick
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CAUTION!
Do not use abrasive or strong cleaning materials such
as steel wool or scouring powder, which will scratch
metal and painted surfaces.
Special Care
•
If you drive on salted or dusty roads or if you drive
near the ocean, hose off the undercarriage at least once
a month.
•It is important that the drain holes in the lower edges
of the doors and rocker panels be kept clear and open.
•If you detect any stone chips or scratches in the paint,
touch them up immediately. The cost of such repairs is
considered the responsibility of the owner.
•If your vehicle is damaged due to an accident or
similar cause which destroys the paint and protectivecoating, have your vehicle repaired as soon as pos-
sible. The cost of such repairs is considered the respon-
sibility of the owner.
•If you carry special cargo such as chemicals, fertilizers,
de-icer salt, etc., be sure that such materials are well
packaged and sealed.
•If a lot of driving is done on gravel roads, consider
mud or stone shields behind each wheel.
•Use MOPARTouch Up Paint on scratches as soon as
possible. Your authorized dealer has touch up paint to
match the color of your vehicle.
Wheel and Wheel Trim Care
All wheels and wheel trim, especially aluminum and
chrome-plated wheels, should be cleaned regularly with
a mild soap and water to prevent corrosion. To remove
heavy soil and/or excessive brake dust, use MOPAR
Wheel Cleaner (P/N 05066247AB) or equivalent or select
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The numbers inside the TIPM cover correspond to the
following table.
FUSES/TIPM
CavityCartridge
FuseMini-
FuseDescription
J1 40 Amp
Green— Power Folding Seat
J2 30 Amp
Pink— Power Liftgate Mod-
ule
J3 40 Amp
Green— Rear Door Module
(RR Door Node)
J4 25 Amp
Natural— Driver Door Node
J5 25 Amp
Natural— Passenger Door Node
J6 40 Amp
Green— Anti-Lock Brake Sys-
tem (ABS) Pump/ESP
J7 30 Amp
Pink— Anti-Lock Brake Sys-
tem (ABS) Valve
FUSES/TIPM
CavityCartridge
FuseMini-
FuseDescription
J8 40 Amp
Green— Power Memory Seat
(If Equipped)
J9 40 Amp
Green— PZEV Motor/Flex
Fuel
J10 30 Amp
Pink— Headlamp Wash
Relay/Manual Tuning
Valve
J11 30 Amp
Pink— Power Sliding Door
Module
J13 60 Amp
Yellow— Ignition Off Draw
(IOD) — Main
J14 40 Amp
Green— Rear Window Defog-
ger
J15 30 Amp
Pink— Rear Blower
J17 40 Amp
Green— Starter Solenoid
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