cooling DODGE CARAVAN 2005 4.G User Guide

Cooling System
Inspection
WARNING!
•When 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.
•You 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
Check engine coolant (antifreeze) protection every 12
months (before 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 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
from the radiator drain cock. If the cap is sealing prop-
erly, the coolant will begin to drain from the coolant
394 MAINTAINING YOUR VEHICLE

recovery bottle. DO NOT REMOVE THE COOLANT
PRESSURE CAP WHEN THE COOLING SYSTEM IS
HOT.
Cooling System—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!
•Mixing of coolants other than specified engine
coolant, may result in engine damage, and de-
crease corrosion protection. If a non-HOAT cool-
ant is introduced into the cooling system in an
emergency, it should be replaced with the speci-
fied coolant as soon as possible.
•Do not use plain water alone or alcohol base
engine coolant (antifreeze) products. Do not use
additional rust inhibitors or antirust products, as
they may not be compatible with the radiator
engine coolant and may plug the radiator.
•This 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 395
7

Adding Coolant
When adding coolant, or refilling the system, a minimum
solution of 50% recommended HOAT ethylene glycol
engine coolant (antifreeze) and distilled water should be
used. Use higher concentrations (not to exceed 70%) if
temperatures below
34°F(
37°C) are anticipated.
Use only high purity water such as distilled or deionized
water when mixing the water/engine coolant 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.
Cooling System Pressure Cap
The 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 cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.
396 MAINTAINING YOUR VEHICLE

WARNING!
•The warning words“DO NOT OPEN HOT”on
the cooling system pressure cap are a safety pre-
caution. Never add coolant 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
engine damage may result.
Disposal of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. To prevent ingestion by animals or childrendo not store ethylene glycol based engine coolant 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 recovery bottle provides a quick visual
method for determining that the coolant level is ad-
equate. With the engine cold, the level of the coolant in
the coolant recovery bottle should be between the
“MAX”and“MIN”marks. The radiator normally re-
mains completely full, so there is no need to remove the
radiator cap except for checking coolant freeze point or
replacement with new antifreeze coolant. Your service
attendant should be advised of this. So long as the engine
operating temperature is satisfactory, the coolant recov-
ery bottle need only be checked once a month.
MAINTAINING YOUR VEHICLE 397
7

When additional coolant is needed to maintain the
proper level, it should be added to the coolant recovery
bottle. Do not overfill.
Points to Remember
NOTE:When the vehicle is stopped after a few miles 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 accumulat-
ing on the radiator and being vaporized when the
thermostat opens, allowing hot water to enter the radia-
tor.
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 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.
•If 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.
•Maintain coolant concentration at 50% HOAT ethylene
glycol engine coolant (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, keep the front of the
condenser clean, also.
398 MAINTAINING YOUR VEHICLE

•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 cooling performance.
•Increasing 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.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.
MAINTAINING YOUR VEHICLE 399
7

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.
FLUIDS AND CAPACITIES
U.S. Metric
Fuel (Approximate) 87
Octane20 Gallons 76 Liters
Engine Oil-with filter
2.4 Liter Engines (SAE 5W-30, API Certified) 5.0 qts 4.7 Liters
3.3 & 3.8 Liter Engines (SAE 5W-20, API Certified) 5.0 qts 4.7 Liters
Cooling System *
2.4 Liter Engines (MoparAntifreeze/Coolant 5 Year/100,000
Mile Formula)11.4 qts 10.7 Liters
3.3 & 3.8 Liter Engines (MoparAntifreeze/Coolant 5 Year/
100,000 Mile Formula)†13.4 qts 12.6 Liters
* Includes heater and coolant recovery bottle filled to MAX level.
†* Add 2.9 quarts (2.8 liters) if equipped with a rear heater.
MAINTAINING YOUR VEHICLE 421
7

Computer, Trip/Travel.................... 154
Console, Overhead....................... 150
Console, Removable...................176,178
Contract, Service........................ 450
Coolant Pressure Cap..................... 396
Cooling System......................... 394
Adding Coolant (Antifreeze).............. 396
Coolant Capacity...................... 421
Coolant Level......................394,397
Disposal of Used Coolant................ 397
Drain, Flush, and Refill.................. 395
Inspection........................... 394
Points to Remember.................... 398
Pressure Cap......................... 396
Radiator Cap......................... 396
Selection of Coolant...............395,421,422
Cruise Control (Speed Control).............. 147
Cruise Light........................... 204
Cup Holder.........................170,410Customer Assistance..................... 449
Daytime Running Lights................... 137
Dealer Service.......................... 378
Defroster, Rear Window................... 287
Defroster, Windshield................84,267,278
Diagnostic System, Onboard................ 376
Digital Video Disc Player.................. 243
Dimmer Control........................ 135
Dipsticks
Automatic Transmission................. 404
Oil (Engine).......................... 379
Disarming, Theft System................... 28
Disposal
Antifreeze (Engine Coolant)............... 397
Engine Oil........................... 383
Domelight............................. 135
Door Ajar Light......................... 197
Door Locks............................. 17
INDEX 461
10

Door Locks, Automatic.................... 19
Door Opener, Garage..................... 159
Drive Belts............................ 383
Drive Shaft Universal Joints................ 391
Driving
On Slippery Surfaces.................... 367
DVD Player............................ 243
Electric Remote Mirrors.................... 94
Electrical Power Outlets................... 168
Electronic Speed Control................... 147
Electronic Vehicle Information Center......... 155
Emergency, In Case of
Hazard Warning Flasher................. 344
Jacking........................346,347,359
Jump Starting......................... 365
Overheating.......................... 345
Emission Control System Maintenance......377,426
Engine............................374,375Air Cleaner.......................... 385
Air Cleaner Filter...................... 384
Block Heater......................... 296
Break-In Recommendations................ 82
Checking Oil Level..................... 379
Compartment......................374,375
Coolant (Antifreeze).................... 422
Cooling............................. 394
Exhaust Gas Caution..................38,333
Fails to Start.......................293,295
Fuel Requirements..................330,421
Oil ...........................379,421,422
Oil Change Interval.................... 381
Oil Disposal.......................... 383
Oil Filler Cap......................... 382
Oil Filter Disposal...................... 383
Oil Selection.......................381,421
Oil Synthetic......................... 383
Overheating.......................... 345
462 INDEX