brake DODGE CARAVAN 2011 Workshop Manual

WARNING!
Riding the brakes can lead to brake failure and
possibly a collision. 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 would not 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.
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 “Main-
taining Your Vehicle” for further information.
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WARNING!
•Use only manufacturer’s recommended brake
fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further
information. Using the wrong type of brake fluid
can severely damage your brake system and/or
impair its performance. The proper type of brake
fluid for your vehicle is also identified on the
original factory installed hydraulic master cylin-
der reservoir.(Continued)
WARNING! (Continued)
•To avoid contamination from foreign matter or
moisture, use only new brake fluid or fluid that
has been in a tightly closed container. Keep the
master cylinder reservoir cap secured at all times.
Brake fluid in a open container absorbs moisture
from the air resulting in a lower boiling point.
This may cause it to boil unexpectedly during hard
or prolonged braking, resulting in sudden brake
failure. This could result in a collision.
•Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts, causing
the brake fluid to catch fire. Brake fluid can also
damage painted and vinyl surfaces, care should be
taken to avoid its contact with these surfaces.(Continued)
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WARNING! (Continued)
•Do not allow petroleum based fluid to contami-
nate the brake fluid. Brake seal components could
be damaged, causing partial or complete brake
failure. This could result in a collision.
Automatic Transmission
The automatic transmission and differential assembly are
contained within a single housing.
The fluid level in the automatic transmission should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transmission and the fluid.
The six–speed transmission is equipped with a capped
dipstick tube. It is sealed and should not be tampered
with. Your authorized dealer has the necessary tools to
ensure that the fluid level is set properly.
Selection Of Lubricant
It is important that the proper lubricant is used in the
transmission to assure optimum transmission perfor-
mance. Use only the manufacturer’s recommended trans-
mission fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further informa-
tion. It is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluid. No chemical flushes should be used in any trans-
mission; only the approved lubricant may be used.
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•If a lot of driving is done on gravel roads, consider
mud or stone shields behind each wheel.
•Use MOPARTouch Up Paint or equivalent 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 or equivalent or select a nonabrasive,
non-acidic cleaner. Do not use scouring pads, steel wool,
a bristle brush, or metal polishes. Only MOPAR or
equivalent is recommended. Do not use oven cleaner.
Avoid automatic car washes that use acidic solutions or
harsh brushes that may damage the wheels protective
finish.
Stain Repel Fabric Cleaning Procedure – If
Equipped
Stain Repel seats may be cleaned in the following man-
ner:
•Remove as much of the stain as possible by blotting
with a clean, dry towel.
•Blot any remaining stain with a clean, damp towel.
•For tough stains, apply MOPAR Total Clean or
equivalent, or a mild soap solution to a clean, damp
cloth and remove the stain. Use a fresh, damp towel to
remove soap residue.
•For grease stains, apply MOPAR Multi-Purpose
Cleaner or a equivalent high quality cleaner to a clean,
damp cloth and remove the stain. Use a fresh, damp
towel to remove soap residue.
•Do not use any harsh solvents or any other form of
protectants on Stain Repel products.
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The numbers inside the TIPM cover correspond to the
following table.
CavityCartridge
Fuse Mini-Fuse Description
J1 40 Amp Green — Power Folding Seat
J2 30 Amp Pink — Power Liftgate Mod-
ule
J3 30 Amp Pink — Rear Door Module
(RR Door Node)
J4 25 Amp Natural — Driver Door Node
J5 25 Amp Natural — Passenger Door
Node
J6 40 Amp Green — Antilock Brakes
Pump/Stability Con-
trol System
Cavity Cartridge
Fuse Mini-Fuse Description
J7 30 Amp Pink — Antilock Brakes
Valve/Stability Con-
trol System
J8 40 Amp Green — Power Memory Seat
– If Equipped
J9 40 Amp Green — Partial Zero Emis-
sions Vehicle Motor/
Flex Fuel
J10 30 Amp Pink — Headlamp Wash
Relay/Manifold
Tuning Valve
J11 30 Amp Pink — Power Sliding Door
Module/Anti–Theft
Module Relay Lock
Feed
J13 60 Amp Yellow — Ignition Off Draw
(IOD) – Main
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CavityCartridge
Fuse Mini-Fuse Description
J14 40 Amp Green — Rear Window De-
fogger
J15 30 Amp Pink — Front Blower
J17 40 Amp Green — Starter Solenoid
J18 20 Amp Blue — Powertrain Control
Module Trans Range
J19 60 Amp Yellow — Radiator Fan
J20 30 Amp Pink — Front Wiper LO/HI
J21 20 Amp Blue — Front/Rear Washer
J22 25 Amp Natural — Sunroof ModuleCavity
Cartridge
Fuse Mini-Fuse Description
M1 — 15 Amp BlueRear Center Brake
Lamp/Brake Switch
M2 — — —
M3 — 20 Amp YellowSpare Fuse
M4 — 10 Amp RedTrailer Tow
M5 — 25 Amp NaturalInverter
M6 — 20 Amp YellowPower Outlet #1
(ACC), Rain Sensor
M7 — 20 Amp YellowPower Outlet #2
(BATT/ACC SE-
LECT)
M8 — 20 Amp YellowFront Heated Seat –
If Equipped
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CavityCartridge
Fuse Mini-Fuse Description
M37 — 10 Amp RedAntilock Brakes, Sta-
bility Control Sys-
tem, Stop Lamp
Switch, Fuel Pump
Rly Hi Control
M38 — 25 Amp NaturalDoor Lock/Unlock
Motors, Liftgate
Lock/Unlock Motors
The heated mirrors, lower instrument panel power outlet
and removable floor console, when in the front position
are fused with self-resetting fuses that are only serviceable
by an authorized dealer. The power seats are fused by a
30 Amp circuit breaker located under the driver’s seat. The
power windows are fused by a 25 Amp circuit breaker
located under the instrument panel near the steering
column. If you experience temporary or permanent loss of
these systems, see your authorized dealer for service.
VEHICLE STORAGE
If you are leaving your vehicle dormant for more than
21 days, you may want to take steps to protect your
battery. You may do the following:
•Remove the 20 Amp mini-fuse in the Totally Inte-
grated Power Module (TIPM) labeled Ignition-Off
Draw (IOD).
•Or, disconnect the negative cable from the battery.
•Anytime you store your vehicle, or keep it out of
service for two weeks or more, run the air conditioning
system at idle for about five minutes in the fresh air
and high blower setting. This will ensure adequate
system lubrication to minimize the possibility of com-
pressor damage when the system is started again.
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Chassis
ComponentFluid, Lubricant, or Genuine Part
Automatic Transmission MOPAR
ATF+4Automatic Transmission Fluid or equivalent licensed
ATF+4 product.
Brake Master Cylinder MOPAR
DOT 3 and SAE J1703 should be used or equivalent. If DOT 3
brake fluid is not available, then DOT 4 is acceptable. Use only recom-
mended brake fluids.
Power Steering Reservoir MOPAR
Power Steering Fluid +4, MOPAR ATF+4Automatic Trans-
mission Fluid or equivalent licensed ATF+4 product.
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•Under no circumstances should oil change intervals
exceed 8,000 miles (13 000 km) or six months, which-
ever comes first.
Your authorized dealer will reset the oil change indicator
message after completing the scheduled oil change. If a
scheduled oil change is performed by someone other
than your authorized dealer, the message can be reset by
referring to the steps described under “Electronic Vehicle
Information Center (EVIC)/Oil Change Required” in
“Understanding Your Instrument Panel” or under “In-
strument Cluster Description/Odometer/Trip Odom-
eter” in “Understanding Your Instrument Panel” for
further information.
At Each Stop For Fuel
•Check the engine oil level about five minutes after a
fully warmed engine is shut OFF. Checking the oil
level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only
when the level is at or below the ADD, SAFE or MIN
mark.
•Check the windshield washer solvent and add if
required.
Once A Month
•Check tire pressure and look for unusual wear or
damage.
•Inspect the battery and clean and tighten the terminals
as required.
•Check the fluid levels of the coolant reservoir, the
brake master cylinder, the power steering and the
transmission and add as needed.
•Check all lights and other electrical items for correct
operation.
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SMAINTENANCE SCHEDULES 517
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At Each Oil Change
•Change the engine oil filter.
•Inspect the brake hoses and lines.
•Open the left and right door (slowly) and inspect for
excessive dirt. If noise exist wipe clean and apply
krytox lube to the door rollers.
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.
Required Maintenance Intervals
Refer to the Maintenance Schedules on the following
pages for the required maintenance intervals.
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S518 MAINTENANCE SCHEDULES
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