cooling DODGE CARAVAN 2004 4.G User Guide

Cooling System
Inspection
WARNING!
²When working near the radiator cooling fan, turn
the ignition key to the OFF position. The fan is
temperature controlled and can start at any time
when the ignition key is in the ON position.
²You or others can be badly burned by hot coolant
or steam from your radiator. If you see or hear
steam coming from under the hood, don't open
the hood until the radiator has had time to cool.
Never try to open a cooling system pressure cap
when the radiator is hot.
Coolant Checks
Coolant protection checks should be made every 12
months (prior to the onset of freezing weather, where
applicable). If coolant is dirty or rusty in appearance, the
system should be drained, flushed and refilled with fresh
coolant. Check the front of the A/C condenser for any
accumulation of bugs, leaves, etc. If dirty, clean by
removing the upper grill support and gently spraying
water from a garden hose vertically down the face of the
condenser.
Check the coolant recovery bottle tubing for brittle rub-
ber, cracking, tears, cuts and tightness of the connection
at the bottle and radiator. Inspect the entire system for
leaks.
With the engine at normal operating temperature (but
not running), check the coolant pressure cap for proper
vacuum sealing by draining a small amount of coolant
318 MAINTAINING YOUR VEHICLE

from the radiator drain cock. If the cap is sealing prop-
erly, the coolant will begin to drain from the coolant
recovery bottle. DO NOT REMOVE THE COOLANT
PRESSURE CAP WHEN THE COOLING SYSTEM IS
HOT.
Cooling System Ð Drain, Flush and Refill
At the intervals shown in the maintenance schedules, the
system should be drained, flushed and refilled.
If the solution is dirty or contains a considerable amount
of sediment, clean and flush with a reliable cooling
system cleaner. Follow with a thorough rinsing to remove
all deposits and chemicals. Properly dispose of old
antifreeze solution.
Selection Of Coolant
Use only the manufacturers recommended coolant, refer
to Recommended Fluids, Lubricants and Genuine Parts
for correct coolant type.
CAUTION!
²Mixing of coolants other than specified (non-
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection. If a non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the speci-
fied coolant as soon as possible.
²Do not use plain water alone or alcohol base
antifreeze products. Do not use additional rust
inhibitors or antirust products, as they may not be
compatible with the radiator coolant and may
plug the radiator.
²This vehicle has not been designed for use with
Propylene Glycol based coolants. Use of Propy-
lene Glycol based coolants is not recommended.
MAINTAINING YOUR VEHICLE 319
7

Adding Coolant
When adding coolant, or refilling the system, a minimum
of 50% solution of ethylene glycol antifreeze coolant in
water should be used. Higher concentrations (not to
exceed 70%) are required if temperatures below237ÉF
(238ÉC) are anticipated.
Use only high purity water such as distilled or deionized
water when mixing the water/antifreeze solution. The
use of lower quality water will reduce the amount of
corrosion protection in the engine cooling system.
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 coolant types will decrease the life of the
engine coolant and will require more frequent coolant
changes.
Coolant Pressure Cap
The coolant pressure cap must be fully tightened to
prevent loss of coolant, and to insure that coolant will
return to the radiator from the coolant recovery bottle.
The coolant pressure cap should be inspected and
cleaned if there is any accumulation of foreign material
on the sealing surfaces.
WARNING!
The warning words ªDO NOT OPEN HOTº on the
coolant pressure cap are a safety precaution. Never
add coolant to the radiator when the engine is over-
heated. Do not loosen or remove the coolant pressure
cap to cool an overheated engine. Heat causes pres-
sure to build up in the cooling system. To prevent
scalding or injury, do not remove the coolant pressure
cap while the system is hot or under pressure.
320 MAINTAINING YOUR VEHICLE

²Check coolant freeze point in the radiator and in the
coolant recovery bottle. If antifreeze needs to be
added, contents of coolant recovery bottle must also be
protected against freezing.
²If frequent coolant additions are required, or if the
level in the coolant recovery bottle does not drop when
the engine cools, the cooling system should be pres-
sure tested for leaks.
²Maintain coolant concentration at 50% ethylene glycol
antifreeze (minimum) in water for proper corrosion
protection of your engine which contains aluminum
components.
²Make sure that the radiator and coolant recovery
bottle overflow hoses are not kinked or obstructed.
²Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean, also.
²Do 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 cooling performance.
²Increasing engine speed at idle does not reduce cool-
ant temperature! Put transmission in NEUTRAL and
let engine idle at normal engine idle speed.
Hoses And Vacuum/Vapor Harnesses
Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.
Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.
322 MAINTAINING YOUR VEHICLE

Center High Mounted Stop Light (CHMSL)
1. Remove the two screws securing the CHMSL.
2. Twist the bulb socket to remove from the CHMSL
housing.
3. Pull the bulb out of the socket.
4. Replace the bulb, reinstall the socket and reattach the
CHMSL.
License Light
1. Remove the two lens assembly mounting screws.
2. Pull the bulb out of the socket. Replace the bulb and
reattach the lens assembly.
FLUID CAPACITIES
U.S. Metric
Fuel (Approximate)20 Gallons 76 Liters
Engine Oil-with filter
2.4 Liter Engine 5.0 qts 4.7 Liters
3.3 & 3.8 Liter Engines 5.0 qts 4.7 Liters
Cooling System *
2.4 Liter Engines 11.4 qts 10.7 Liters
² 3.3 & 3.8 Liter Engines 13.4 qts 12.6 Liters
* Includes heater and coolant recovery bottle filled to
MAX level.
² * Add 2.9 quarts (2.8 liters) if equipped with a rear
heater.
MAINTAINING YOUR VEHICLE 343
7

Cargo Compartment
Luggage Carrier....................... 139
Cassette Tape and Player Maintenance......... 197
Cassette Tape Player..................... 161
Catalytic Converter...................... 309
CD Changer......................170,182,187
CD Player...............167,171,174,178,180,187
Center High Mounted Stop Light............ 343
Center Lap Belts......................... 47
Chains, Tire............................ 263
Changing A Flat Tire..................... 282
Child Restraint.......................... 58
Child Restraint Tether Anchors............... 62
Child Safety Locks........................ 32
Child Seat............................58,64
Clean Air Gasoline....................... 266
Climate Control......................... 199
Clock................................ 159
Compact Disc Maintenance................. 198Compact Disc Player..................161,167
Compact Spare Tire...................... 255
Compass.............................. 111
Compass Calibration..................... 112
Compass Variance....................... 112
Computer, Trip/Travel.................... 114
Console, Overhead....................... 110
Console, Removable...................... 132
Contract, Service........................ 374
Coolant Pressure Cap..................... 320
Cooling System......................... 318
Adding Coolant (Antifreeze).............. 320
Coolant Capacity...................... 343
Coolant Level......................... 321
Disposal of Used Coolant................ 321
Drain, Flush, and Refill.................. 319
Inspection........................... 318
Points to Remember.................... 321
Pressure Cap......................... 320
384 INDEX

Air Cleaner Filter...................... 308
Block Heater......................... 230
Break-In Recommendations................ 70
Checking Oil Level..................... 303
Compartment......................298,299
Coolant............................. 344
Cooling............................. 318
Exhaust Gas Caution..................36,269
Fails to Start.......................227,229
Fuel Requirements..................... 266
Oil ..............................303,344
Oil Change Interval.................... 305
Oil Selection.......................... 305
Oil Synthetic......................... 307
Overheating.......................... 281
Temperature Gauge..................... 154
Exhaust Gas Caution..............36,71,269,317
Exhaust System......................... 317
Exterior Folding Mirrors................... 78Filters
Air Cleaner.......................... 308
Air Conditioning....................219,313
Automatic Transaxle.................... 328
Engine Fuel.......................... 309
Engine Oil........................307,344
Engine Oil Disposal.................... 307
Flashers
Hazard Warning....................... 280
Turn Signal..................158,159,340,342
Fluid Capacities......................... 343
Fluid Leaks............................. 72
Fluid Level Checks
Automatic Transaxle.................... 327
Brake............................... 345
Power Steering.....................314,345
Fog Light Service........................ 341
Fog Lights..........................102,341
Freeing A Stuck Vehicle................... 291
386 INDEX