maintenance schedule DODGE CARAVAN 2004 4.G Owners Manual

TABLE OF CONTENTSSECTIONPAGE
1INTRODUCTION.............................................................3
2THINGS TO KNOW BEFORE STARTING YOUR VEHICLE..............................9
3UNDERSTANDING THE FEATURES OF YOUR VEHICLE..............................73
4UNDERSTANDING YOUR INSTRUMENT PANEL...................................143
5STARTING AND OPERATING.................................................223
6WHAT TO DO IN EMERGENCIES..............................................279
7MAINTAINING YOUR VEHICLE...............................................295
8MAINTENANCE SCHEDULES..................................................347
9IF YOU NEED CONSUMER ASSISTANCE.........................................371
10INDEX....................................................................381
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Snow tires generally have lower speed ratings than what
was originally equipped with your vehicle and should
not be operated at sustained speeds over 75 mph (120
km/h).
TIRE ROTATION RECOMMENDATIONS
Tires on the front and rear axles of vehicles operate at
different loads and perform different steering, driving,
and braking functions. For these reasons, they wear at
unequal rates, and tend to develop irregular wear pat-
terns.
These effects can be reduced by timely rotation of tires.
The benefits of rotation are especially worthwhile with
aggressive tread designs such as those on all season type
tires. Rotation will increase tread life, help to maintain
mud, snow, and wet traction levels, and contribute to a
smooth, quiet ride.
Follow the recommended tire rotation frequency for your
type of driving found in the ªMaintenance SchedulesºSection of this manual. More frequent rotation is permis-
sible if desired. The reasons for any rapid or unusual
wear should be corrected prior to rotation being per-
formed.
NOTE:The Tire Pressure Monitor system must be
retrained following a tire rotation. See your authorized
dealer for service.
The suggested rotation method is the ªforward-crossº
shown in the following diagram.
STARTING AND OPERATING 265
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Front
AxleRear Axle
Empty Weight 2140 lbs 1470 lbs
Load (Including driver, pass-
sengers and cargo)360 lbs 980 lbs
Total 2500 lbs 2450 lbs
GAWR 2544 lbs 2544 lbs
TRAILER TOWING
In this section you will find safety tips and information
on limits to the type of towing you can reasonably do
with your vehicle. Before towing a trailer carefully re-
view this information to tow your load as efficiently and
safely as possible.
To maintain warranty coverage, follow the requirements
and recommendations in this manual concerning ve-
hicles used for trailer towing.Perform maintenance services as prescribed in the main-
tenance schedules manual. When your vehicle is used for
trailer towing, never exceed the gross axle weight rating
(GAWR) by the addition of:
²The tongue weight of the trailer.
²The weight of any other type of cargo or equipment
put in or on your vehicle.
²Remember that everything put in or on the trailer adds
to the load on your vehicle.
Warranty Requirements
The Manufacturer's Passenger Vehicle Warranty will
apply to vehicles used to tow trailers for non-commercial
use. However the following conditions must be met:
²The maximum frontal area of the trailer cannot exceed
20 square feet (1.86 square meters).
STARTING AND OPERATING 275
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ignition key or start the engine. This means that your
vehicle's OBD system isnot readyand you shouldnot
proceed to the I/M station.
b. The MIL will not flash at all and will remain fully
illuminated until you turn off the ignition key or start
the engine. This means that your vehicle's OBD system
isreadyand you can proceed to the I/M station.
If your OBD system isnot ready,you should see your
authorized dealer or repair facility. If your vehicle was
recently serviced or had a battery failure or replacement,
you may need to do nothing more than drive your
vehicle as you normally would in order for your OBD
system to update. A recheck with the above test routine
may then indicate that the system is now ready.
Regardless of whether your vehicle's OBD system is
ready or not ready, if the MIL symbol is illuminated
during normal vehicle operation, you should have yourvehicle serviced before going to the I/M station. The I/M
station can fail your vehicle because the MIL symbol is on
with the engine running.
REPLACEMENT PARTS
Use of genuine Mopartparts for normal/scheduled
maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopartparts for maintenance
and repairs will not be covered by the manufacturer's
warranty.
DEALER SERVICE
Your dealer has the qualified service personnel, special
tools and equipment to perform all service operations in
an expert manner. Service Manuals are available which
include detailed service information for your vehicle.
Refer to these manuals before attempting any procedure
yourself.
302 MAINTAINING YOUR VEHICLE

Synthetic Engine Oils
There are a number of engine oils being promoted as
either synthetic or semi-synthetic. If you chose to use
such a product, useonlythose oils that meet the Ameri-
can Petroleum Institute (API) and SAE viscosity stan-
dard. Follow the service schedule that describes your
driving type.
Materials Added to Engine Oil
The manufacture strongly recommends against the addi-
tion of any additives (other than leak detection dyes) to
the engine oil. Engine oil is an engineered product and
it's performance may be impaired by supplemental ad-
ditives.
Disposing of Used Engine Oil And Oil Filters
Care should be taken in disposing of used engine oil and
oil filters from your vehicle. Used oil and oil filters,
indiscriminately discarded, can present a problem to the
environment. Contact your dealer, service station, orgovernmental agency for advice on how and where used
oil and oil filters can be safely discarded in your area.
Engine Oil Filter
The engine oil filter should be replaced at every engine
oil change.
Engine Oil Filter Selection
All the manufacturers engines have a full-flow type oil
filter. Use a filter of this type for replacement. The quality
of replacement filters varies considerably. Only high
quality filters should be used to assure most efficient
service. Mopar Engine Oil Filters are a high quality oil
filter and are recommended.
Drive Belts Ð Check Condition and Tension
At the mileage indicated in the maintenance schedule, all
belts should be checked for condition and proper tension.
Improper belt tension can cause belt slippage and failure.
MAINTAINING YOUR VEHICLE 307
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WARNING!
²Use only refrigerants approved by this manufac-
turer for your air conditioning system. Some un-
approved refrigerants are flammable and can ex-
plode, injuring you. Other unapproved
refrigerants can cause the system to fail, requiring
costly repairs.
²Never add air conditioning refrigerant to correct a
non-cooling problem unless pressure gauges are
connected to the system by a certified technician.
Lack of cooling could be due to a restriction and
adding refrigerant may cause a dangerous pres-
sure rise and you could be injured.
Refrigerant Recovery And Recycling
The air conditioning system of your vehicle contains
R-134a, a refrigerant that does not deplete the ozone layer
in the upper atmosphere. The manufacturer recommendsthat air conditioning service be done by facilities using
refrigerant recycling and recovery equipment that meets
SAE standard J1991.
A/C Air Filter
The filter access door is located under the instrument
panel on the passenger side. To replace the filter slide the
lock toward the rear of the vehicle (unlock position).
Remove the access door and pull the filter downward.
When installing a new filter, ensure its proper orienta-
tion. Align the black arrow on the bottom of the filter
frame with the direction of airflow (away from the
blower motor and towards the center of the car).
Refer to the ªMaintenance Schedulesº section of this
manual for the recommended air conditioning filter
replacement intervals.
MAINTAINING YOUR VEHICLE 313
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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
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Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.
Brakes
In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the Mainte-
nance Schedules.
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.
Brake And Power Steering Hoses
When the vehicle is serviced for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,
cracking, tears, cuts, abrasion, and excessive swelling
indicate deterioration of the rubber. Particular attention
should be made to examining those hose surfaces nearest
to high heat sources, such as the exhaust manifold.
MAINTAINING YOUR VEHICLE 323
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MAINTENANCE SCHEDULES
CONTENTS
mEmission Control System Maintenance........348
mMaintenance Schedules...................348NSchedule ªBº........................351
NSchedule ªAº........................363
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EMISSION CONTROL SYSTEM MAINTENANCE
The ªScheduledº maintenance services, listed inbold
typemust be done at the times or mileages specified to
assure the continued proper functioning of the emission
control system. These, and all other maintenance services
included in this manual, should be done to provide best
vehicle performance and reliability. More frequent main-
tenance may be needed for vehicles in severe operating
conditions such as dusty areas and very short trip
driving.
Inspection and service also should be done any time a
malfunction is suspected.
NOTE:Maintenance, replacement, or repair of the emis-
sion control devices and systems on your vehicle may be
performed by any automotive repair establishment or
individual using any automotive part which has been
certified pursuant to U.S. EPA or, in the State of Califor-
nia, California Air Resources Board regulations.
MAINTENANCE SCHEDULES
There are two maintenance schedules that show the
requiredservice 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
348 MAINTENANCE SCHEDULES
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