DODGE CARAVAN 2005 4.G Owners Manual

MAINTAINING YOUR VEHICLE
CONTENTS

2.4L Engine...........................374

3.3L/3.8L Engines......................375

Onboard Diagnostic System—OBDII........376

Emissions Inspection And
Maintenance Programs...................377

Replacement Parts......................378

Dealer Service.........................378

Maintenance Procedures..................379
▫Engine Oil..........................379▫Engine Oil Filter......................383
▫Drive Belts—Check Condition And Tension . . 383
▫Spark Plugs.........................384
▫Engine Air Cleaner Filter................384
▫Catalytic Converter....................385
▫Maintenance-Free Battery................387
▫Air Conditioner Maintenance.............388
▫Power Steering—Fluid Check............390
▫Front Suspension Ball Joints..............390
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▫Steering Shaft Seal....................391
▫Steering Linkage......................391
▫Drive Shaft Universal Joints..............391
▫Body Lubrication.....................391
▫Windshield Wiper Blades................392
▫Windshield And Rear Window Washers.....392
▫Exhaust System......................393
▫Cooling System.......................394
▫Hoses And Vacuum/Vapor Harnesses.......399
▫Brakes.............................399
▫Master Cylinder—ABS Brakes Brake
Fluid Level Check.....................401
▫Fuel System Hoses....................402▫Automatic Transmission................402
▫Front And Rear Wheel Bearings...........406
▫Appearance Care And Protection
From Corrosion......................406
▫Cleaning The Instrument Panel And Underseat
Cup Holders........................410

Integrated Power Module (IPM)............412

Vehicle Storage........................415

Replacement Light Bulbs.................415

Bulb Replacement......................416
▫Headlights..........................416
▫Front Park/Turn Signal And
Sidemarker Lights.....................418
▫Front Fog Light......................419
372 MAINTAINING YOUR VEHICLE

▫Rear Tail, Stop, Turn Signal, Side Marker And
Back-Up Lights.......................419
▫Center High Mounted Stop Light (CHMSL) . . . 420
▫License Light........................421

Fluids And Capacities...................421
Recommended Fluids, Lubricants
And Genuine Parts.....................422
▫Engine.............................422
▫Chassis............................423
MAINTAINING YOUR VEHICLE 373
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2.4L ENGINE
Engine Compartment 2.4L Engine
374 MAINTAINING YOUR VEHICLE

3.3L/3.8L ENGINES
Engine Compartment 3.3L/3.8L Engines
MAINTAINING YOUR VEHICLE 375
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ONBOARD DIAGNOSTIC SYSTEM—OBD II
Your vehicle is equipped with a sophisticated onboard
diagnostic system called OBD II. This system monitors
the performance of the emissions, engine, and automatic
transmission control systems. When these systems are
operating properly, your vehicle will provide excellent
performance and fuel economy, as well as engine emis-
sions well within current government regulations.
If any of these systems require service, the OBD II system
will turn on the“Malfunction Indicator Light.”It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be drivable and not
need towing, see your dealer for service as soon as
possible.CAUTION!
•Prolonged driving with the“Malfunction Indica-
tor Light”on could cause further damage to the
emission control system. It could also affect fuel
economy and driveability. The vehicle must be
serviced before any emissions tests can be per-
formed.
•If the“Malfunction Indicator Light”is flashing
while the engine is running, severe catalytic con-
verter damage and power loss will soon occur.
Immediate service is required.
376 MAINTAINING YOUR VEHICLE

EMISSIONS INSPECTION AND MAINTENANCE
PROGRAMS
In some localities, it may be a legal requirement to pass
an inspection of your vehicle’s emissions control system.
Failure to pass could prevent vehicle registration.
For states which have an I/M (Inspection and
Maintenance) requirement, this check verifies the
following: the MIL (Malfunction Indicator Lamp)
is functioning and is not on when the engine is running,
and that the OBD (On Board Diagnostic) system is ready
for testing.
Normally, the OBD system will be ready. The OBD
system maynotbe ready if your vehicle was recently
serviced, if you recently had a dead battery, or a battery
replacement. If the OBD system should be determined
not ready for the I/M test, your vehicle may fail the test.Your vehicle has a simple ignition key actuated test
which you can use prior to going to the test station. To
check if your vehicle’s OBD system is ready, you must do
the following:
1. Insert your ignition key into the ignition switch.
2. Turn the ignition to the ON position, but do not crank
or start the engine.
3. If you crank or start the engine, you will have to start
this test over.
4. As soon as you turn your key to the ON position, you
will see your MIL symbol come on as part of a normal
bulb check.
5. Approximately 15 seconds later, one of two things will
happen:
a. The MIL will flash for about 10 seconds and then
return to being fully illuminated until you turn off the
MAINTAINING YOUR VEHICLE 377
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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 Moparparts for normal/scheduled
maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Moparparts 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.
378 MAINTAINING YOUR VEHICLE

NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
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 proper equipment.
If you have any doubt about your ability to perform
a service job, take your vehicle to a competent
mechanic.
MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.
Engine Oil
Checking Oil Level
To assure proper engine lubrication, the engine oil must
be maintained at the correct level. Check the oil level at
regular intervals, such as every fuel stop.
MAINTAINING YOUR VEHICLE 379
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The best time to check the engine oil level is about 5
minutes after a fully warmed engine is shut off or before
starting the engine after it has sat overnight.
Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Maintain
the oil level between the MIN and MAX markings on the
dipstick. Adding one quart of oil when the reading is at
the MIN mark will result in a MAX reading on these
engines.
CAUTION!
Overfilling or underfilling will cause oil aeration or
loss of oil pressure. This could damage your engine.
Engine Oil Dipstick
380 MAINTAINING YOUR VEHICLE