engine DODGE GRAND CARAVAN 2009 5.G Owners Manual

Please note that it is the owner’s responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated.
NOTE:Mixing engine coolant (antifreeze) types will
decrease the life of the engine coolant (antifreeze) and
will require more frequent coolant changes.
Cooling System Pressure Cap
The cap must be fully tightened to prevent the loss of
engine coolant (antifreeze), and to ensure that engine
coolant (antifreeze) will return to the radiator from the
coolant recovery bottle.
The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces. WARNING!

The warning words “DO NOT OPEN HOT” on
the cooling system pressure cap are a safety pre-
caution. Never add engine coolant (antifreeze)
when the engine is overheated. Do not loosen or
remove the cap to cool an overheated engine. Heat
causes pressure to build up in the cooling system.
To prevent scalding or injury, do not remove the
pressure cap while the system is hot or under
pressure.
Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or en-
gine damage may result.
Disposal of Used Coolant
Used ethylene glycol-based engine coolant (antifreeze) is
a regulated substance requiring proper disposal. Check
with your local authorities to determine the disposal
454 MAINTAINING YOUR VEHICLE

rules for your community. To prevent ingestion by ani-
mals or children, do not store ethylene glycol-based
engine coolant (antifreeze) in open containers or allow it
to remain in puddles on the ground. If ingested by a
child, contact a physician immediately. Clean up any
ground spills immediately.
Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine cold, the level of the engine coolant (antifreeze) in
the coolant recovery bottle should be between the ranges
indicated on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
engine coolant (antifreeze) freeze point or replacing the
engine coolant (antifreeze). Advise your service atten-
dant of this. As long as the engine operating temperature
is satisfactory, the coolant bottle only needs to be checked
once a month.When additional engine coolant (antifreeze) is needed to
maintain the proper level, it should be added to the
coolant bottle. Do not overfill.
Points to Remember
NOTE:
When the vehicle is stopped after a few miles (a
few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high
humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot engine
coolant (antifreeze) to enter the radiator.
If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.
Do not overfill the coolant recovery bottle.
Check the engine coolant (antifreeze) freeze point in
the radiator and in the coolant recovery bottle. If
MAINTAINING YOUR VEHICLE 455 7

engine coolant (antifreeze) needs to be added, contents
of the coolant recovery bottle must also be protected
against freezing.
If frequent engine coolant (antifreeze) additions are
required, or if the level in the coolant recovery bottle
does not drop when the engine cools, the cooling
system should be pressure tested for leaks.
Maintain engine coolant (antifreeze) concentration at
50% HOAT engine coolant (antifreeze) (minimum)
and distilled water for proper corrosion protection of
your engine, which contains aluminum components.
Make sure that the radiator and coolant recovery
bottle overflow hoses are not kinked or obstructed.
Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, also keep the front of
the condenser clean.
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 would not have your full
braking capacity in an emergency.
456 MAINTAINING YOUR VEHICLE

Master Cylinder — Brake Fluid Level CheckThe 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 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.
Use of a brake fluid that has a lower initial boiling
point than the recommended MOPARt DOT 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.
MAINTAINING YOUR VEHICLE 457 7

CAUTION!Using a transmission fluid other than the manufac-
turer’s recommended fluid may cause deterioration
in transaxle shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturer’s recommended fluid will result in
more frequent fluid and filter changes. Refer to
“Fluids, Lubricants and Genuine Parts” in this sec-
tion for the correct fluid type.
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 the parking brake.
4. Place the shift lever momentarily into each gear posi-
tion, ending with the shift lever in PARK. Wipe the area
around the dipstick clean to eliminate the possibility of
dirt entering the transaxle.
MAINTAINING YOUR VEHICLE 459
7

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 the dipstick and note reading.a. If the fluid is hot, the reading should be in the
crosshatched area marked “HOT” (between the upper
two holes in the dipstick).
b. If the fluid is cold, the fluid level should be between
the lower two holes in the area marked “COLD”.
If the fluid level indicates that it is low, add sufficient
fluid to bring it to the proper level. CAUTION!
Do not overfill. Dirt and water in the transaxle can
cause serious damage. To prevent dirt and water from
entering the transaxle after checking or replenishing
fluid, make certain that the dipstick cap is reseated
properly.
Fluid and Filter Changes
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.
If the transaxle is disassembled for any reason, the fluid
and filter should be changed.
Special Additives
Automatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transaxle. The only exception to this policy is
460 MAINTAINING YOUR VEHICLE

Soak the liner in a mixture of medium hot tap water and
one teaspoon of mild liquid dish soap. Let soak for
approximately 30 minutes. After 30 minutes, pull the
liner from the water and dip it back into the water about
six times. This will loosen any remaining debris. Rinse
the liner thoroughly under warm running water. Shake
the excess water from the liner and dry the outer surfaces
with a clean soft cloth.
Installation
Place the liner into the cupholder drawer and press the
liner into place so that the retention tabs seat into the
corresponding openings in the drawer.
FUSES
Totally Integrated Power Module (TIPM)
The Totally Integrated Power Module (TIPM) is located
in the engine compartment near the battery. Refer to the
applicable “Engine Compartment” illustration in thissection. This center contains cartridge fuses and mini-
fuses. A label that identifies each component may be
printed or embossed on the inside of the cover. CAUTION!

When installing the Totally Integrated Power
Module cover, it is important to ensure the cover is
properly positioned and fully latched. Failure to
do so may allow water to get into the Integrated
Power Module, and possibly result in a electrical
system failure.
When replacing a blown fuse, it is important to
use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated
may result in a dangerous electrical system over-
load. If a properly rated fuse continues to blow, it
indicates a problem in the circuit that must be
corrected.
MAINTAINING YOUR VEHICLE 467 7

FUSES/TIPM
Cavity Cartridge
Fuse Mini-
Fuse Description
M28 — 10 Amp RedNext Generation Con-
troller (NGC), PCM,
Transmission Feed
(TRANS FEED), TCM
M29 — 10 Amp RedOccupant Classifica-
tion Module (OCM)
M30 — 15 Amp BlueRear Wiper Module
(RR WIPER MOD),
Power Folding Mirror
(PWR FOLD MIR),
J1962 Diagnostic FeedFUSES/TIPM
Cavity Cartridge
Fuse Mini-
Fuse Description
M31 — 20 Amp YellowBack-Up Lamps
(B/U LAMPS)
M32 — 10 Amp RedOccupant Restraint
Controller (ORC), TT
EUROPE
M33 — 10 Amp RedNext Generation Con-
troller (NGC), Global
Powertrain Engine
Controller (GPEC),
TCM
MAINTAINING YOUR VEHICLE 473 7

FLUIDS AND CAPACITIESU.S.
Metric
Fuel (Approximate) 20 Gallons76 Liters
Engine Oil with Filter
3.3L and 3.8L Engine (SAE 5W-20, API Certified) 5 Quarts4.7 Liters
4.0L Engine (SAE 10W-30, API Certified) 5.5 Quarts5.2 Liters
Cooling System *
3.3L, 3.8L, and 4.0L Engine (MOPARt Engine Coolant/
Antifreeze 5 Year/100,000 Mile Formula) 13.4 Quarts
12.6 Liters
* Includes heater and coolant recovery bottle filled to MAX level. Add 2.9 Qts (2.8 L) if equipped with a rear
heater.
480 MAINTAINING YOUR VEHICLE

FLUIDS, LUBRICANTS AND GENUINE PARTS
EngineComponent
Fluid, Lubricant, or Genuine Part
Engine Coolant MOPARt
Antifreeze/Coolant Five Year/100,000 Mile Formula HOAT
(Hybrid Organic Additive Technology)
Engine Oil (3.3L and 3.8L Engines) Use API Certified SAE 5W-20 Engine Oil, meeting the requirements of
Chrysler Material Standard MS-6395. Refer to your oil filler cap for
correct SAE grade
Engine Oil (4.0L Engine) Use API Certified SAE 10W-30 Engine Oil, meeting the requirements
of Chrysler Material Standard MS-6395. Refer to your oil filler cap for
correct SAE grade
Engine Oil Filter MOPARtEngine Oil Filter or equivalent
Spark Plugs (3.3L and 3.8L Engines) RE14PLP5 (Gap 0.050 in [1.27 mm])
Spark Plugs (4.0L Engine) ZFR5LP-13G (Gap 0.050 in [1.27 mm])
Fuel Selection (3.3L and 3.8L Engines) 87 Octane
Fuel Selection (4.0L Engine) 87 Octane Acceptable — 89 Recommended
MAINTAINING YOUR VEHICLE 481 7