check engine CHRYSLER CARAVAN 2005 Service Manual

POSITION INTERPRETATION CODE = DESCRIPTION
6 Series2 = Low Line
3 = Medium
4 = High Line
5 = Premium
6 = Sport
7 = Special
6 - Export Series B = 4-Speed Automatic Transaxle
N = 5-Speed Manual Transaxle
7 Body Style1 = Van - Caravan C/V
3 = Extended Van - Grand Caravan C/V
4 = Extended Wagon - Grand Caravan/Town & Country
5 = Wagon - Caravan, Voyager, Town & Country
7 - Export Body Style1 = EURO Wagon - Long Wheelbase (RG - 53 - S Series)
2 = EURO Wagon - Short Wheelbase (RG - 52 - H Series)
3 = EURO Wagon - Short Wheelbase (RG - 52 - P Series)
4 = EURO Wagon - Long Wheelbase (RG - 53 - P Series)
5 = EURO Wagon - Long Wheelbase (RG - 53 - H Series)
6 = Commercial Van - Short Wheelbase (with- Sales Code -
CYX Less AS8)
7 = Commercial Van - Short Wheelbase (with Sales Code -
AS8)
8 = Commercial Van-Long Wheelbase (H - Series with Sales
Code - CYX)
9 = Commercial Van - Long Wheelbase (P - Series with
Sales Code - CYX)
8 EngineB = 2.4L I4 Cyl. 16-Valve Gasoline DOHC (MPI)
E = 3.3L V6 Cyl. OHV Flex Fuel
L = 3.8L V6 Cyl. Gasoline (SMPI)
R = 3.3L V6 Cyl. OHV Gasoline
5 = 2.8L I4 Cyl. Turbo Diesel
7 = 2.5L I4 Cyl. 16 Valve Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 5 = 2005
11 Assembly Plant B = St. Louis Assembly South
R = Windsor Assembly
U = Eurostar Gesellschaftz Assembly
12 through 17 Sequence Number A six digit number assigned by assembly plant.
10 INTRODUCTIONRS
VEHICLE IDENTIFICATION NUMBER (Continued)

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION..........................1
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND
LUBRICANTS.........................1
DESCRIPTION - ENGINE COOLANT........3
DESCRIPTION - FLEXIBLE FUEL ENGINE
OIL .................................3
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID.....................4
DESCRIPTION - FUEL REQUIREMENTS.....4
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................6
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................6
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS......................6
DESCRIPTION - AWD POWER TRANSFER
UNIT FLUID...........................6FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......6
FLUID FILL/CHECK LOCATIONS
DESCRIPTION..........................7
LUBRICATION POINTS
DESCRIPTION..........................7
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION........................7
DESCRIPTION - EXPORT...............13
DESCRIPTION - DIESEL ENGINES -
EXPORT............................21
HOISTING
STANDARD PROCEDURE - HOISTING.......24
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 25
TOWING
STANDARD PROCEDURE - TOWING........26
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
Fig. 1 INTERNATIONAL SYMBOLS
RSLUBRICATION & MAINTENANCE0-1

properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformu-
latedº gasoline. Reformulated gasoline contain oxy-
genates, and are specifically blended to reduce
vehicle emissions and improve air quality.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro-
vide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasoline free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may beadversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle's catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
²The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)

FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill point locations are located in
each applicable service manual section.
LUBRICATION POINTS
DESCRIPTION
Lubrication point locations are located in each
applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 32É F (0É
C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90É F (32É C).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Second is ScheduleªAº. It is for vehicles that are
not operated under any of the conditions listed under
Schedule9B9.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 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 or MIN
mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder and transmission, add as needed.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Check the automatic transmission fluid level.
²Check the coolant level, hoses, and clamps.
SCHEDULE B
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
Change the automatic transmission fluid and filter
every 60,000 miles (96 000 km) if the vehicle is usu-
ally operated under one or more of the conditions
marked with anL.
²Day or night temperatures are below 32É F (0É
C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90É F (32É C).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
RSLUBRICATION & MAINTENANCE0-7

Miles 57, 000 60, 000 63, 000 66, 000 69, 000 72, 000
(Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *X XXX X
Replace theengine air
cleaner filter.X
Inspect the tie rod ends and
boot seals.X
Inspect thePCV valveand
replace if necessary.*X
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
³X
Change the automatic
transmission fluid and filter.LX
Replace the air conditioning
filter.XX
Miles 75, 000 78, 000 81, 000 84, 000 87, 000 90, 000
(Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXXX
Replace theengine air
cleaner filterXX
Replace thespark plugson
3.3 liter and 3.8 liter engines.X
Replace theignition cables
3.3 liter and 3.8 liter engines.X
Inspect the tie rod ends and
boot seals.X
Check thePCV valveand
replace if necessary. Not
required if previously
changed.*X
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary. ³XX
Replace the air conditioning
filter.X
RSLUBRICATION & MAINTENANCE0-9
MAINTENANCE SCHEDULES (Continued)

SCHEDULE A
Miles 6, 000 12, 000 18, 000 24, 000 30, 000 36, 000
(Kilometers) (10 000) (19 000) (29 000) (38 000 ) (48 000) (58 000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires X X X X X X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXX X X
Replace theengine air
cleaner filter.X
Inspect the tie rod ends and
boot seals.X
Replace the air conditioning
filter.XX X
Miles 42, 000 48, 000 54, 000 60, 000 66, 000 72, 000
(Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXX X X
Replace theengine air
cleaner filter.X
Inspect the tie rod ends and
boot seals.X
Check thePCV valveand
replace, if necessary.*X
Inspect the serpentine drive
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
³XX
Flush and replace the engine
coolant at 60 months,
regardless of mileage.X
Replace the air conditioning
filter.XX X
RSLUBRICATION & MAINTENANCE0-11
MAINTENANCE SCHEDULES (Continued)

Miles 78, 000 84, 000 90, 000 96, 000 100, 000
(Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter.XXXX
Rotate TiresXXXX
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *XX X X
Replace theengine air cleaner filter.X
Inspect the tie rod ends and boot seals. X
Check and replace thePCV valve,if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
and 3.8 liter engines, replace if necessary. ³X
Replace thespark plugs3.3 liter and 3.8
liter engines.X
Replace theignition cables3.3 liter and
3.8 liter engines.X
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.X
Replace the air conditioning filter. X X
Miles 102, 000 108, 000 114, 000 120, 000
(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Change engine oil and engine oil filter. X X X X
Rotate Tires X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace if necessary. * X X X
Replace theengine air cleaner filter.X
Inspect the tie rod ends and boot seals. X
Check thePCV valveand replace, if necessary.* X
Inspect the serpentine drive belt on 3.3 liter and 3.8 liter
engines, replace if necessary. ³XX
Flush and replace the engine coolant at 120 months, if
not done at 100,000 miles (160 000 km).X
Replace the air conditioning filter. X X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
0 - 12 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

DESCRIPTION - EXPORT
There are two maintenance schedules that show
therequiredservice for your vehicle.
First is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under
Schedule9B9.
Second is ScheduleªBº. It is for vehicles that are
operated under the conditions that are listed below
and at the beginning of the schedule.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.L
²Taxi, police, or delivery service (commercial ser-
vice).L
²Off-road or desert operation.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule(B(.
Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
the interval that occurs first.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
²Check the engine oil level about 5 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 or MIN
mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the battery and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder and transmission, add as needed.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints and front suspension com-
ponents.
²Check the automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
SCHEDULE A - EXPORT ONLY
Kilometers 12 000 24 000 36 000 48 000 60 000 72 000
(Miles) (7,500) (15,000) (22,500 (30,000) (37,500) (45,000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXX X X
Replace theengine air
cleaner filter.X
Replace thespark plugson
2.4 liter engines.X
Inspect the tie rod ends and
boot seals.X
Replace the air conditioning
filter.XX X
RSLUBRICATION & MAINTENANCE0-13
MAINTENANCE SCHEDULES (Continued)

Kilometers 84 000 96 000 108 000 120 000 132 000 144 000
(Miles) (52,500) (60,000) (67,500) (75,000) (82,500) (90,000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine
oil filter.XXXXX X
Rotate Tires XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *X XXX
Replace theengine air
cleaner filter.XX
Replace thespark plugson
2.4 liter engines.XX
Replace theignition cables
on 2.4 liter engines.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.XX
Inspect the tie rod ends and
boot seals.XX
Inspect the generator belt on
2.4 liter engines, replace if
necessary.XX
Check thePCV valveand
replace, if necessary.*XX
Inspect the serpentine drive
belt on 3.3 liter engines,
replace if necessary. ³XX X
Flush and replace the engine
coolant at 60 months,
regardless of mileage.X
Replace the air conditioning
filter.XX X
Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter. X X X X
Rotate Tires X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 2.4 liter
engines.X
0 - 14 LUBRICATION & MAINTENANCERS
MAINTENANCE SCHEDULES (Continued)

Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.XX
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check and replace thePCV valve,if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
engines, replace if necessary. ³XX
Replace thespark plugs3.3 liter engines. X
Replace theignition cables3.3 liter
engines.X
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.X
Replace theengine timing belton 2.4 liter
engines only.X
Replace the air conditioning filter. X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.
RSLUBRICATION & MAINTENANCE0-15
MAINTENANCE SCHEDULES (Continued)