engine DODGE CARAVAN 2005 4.G Repair Manual

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

Change Engine Oil
Road conditions and your kind of driving affects the
interval at which your oil should be changed. Check the
following list to see if any apply to you.
•Day or night temperatures are below 32°F(0°C).
•Stop and Go driving.
•Extensive engine idling.
•Driving in dusty conditions.
•Short trips of less than 10 miles (16 km).
•More than 50% of your driving is at sustained high
speeds during hot weather, above 90°F (32°C).
•Trailer towing.
•Taxi, Police or delivery service (commercial service).
•Off-Road or desert operation.IfANYof these apply to you, then change your engine oil
at every interval shown in schedule“B”of the“Mainte-
nance Schedules”section of this manual.
If none of these apply to you, then change your engine oil
at every interval shown on schedule“A”of the“Main-
tenance Schedules”section of this manual
NOTE:Under no circumstances should oil change in-
tervals exceed 6000 miles (10 000 km) or 6 months
whichever comes first.
Engine Oil Selection
For best performance and maximum protection under all
types of operating conditions, the manufacturer only
recommends engine oils that are API certified and meet
the requirements of DaimlerChrysler Material Standard
MS-6395.
MAINTAINING YOUR VEHICLE 381
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American Petroleum Institute (API) Engine Oil
Identification Symbol
This symbol means that the oil has
been certified by the American
Petroleum Institute (API). The
manufacturer only recommends
API Certified engine oils.
Engine Oil Viscosity (SAE Grade)—2.4 Liter
Engines
SAE 5W-30 engine oil is recommended for all operating
temperatures. This engine oil improves low temperature
starting and vehicle fuel economy. Refer to your engine
oil filler cap for the recommended engine oil viscosity for
your vehicle.For information on engine oil filler cap location, refer to
the Engine Compartment illustration in this section.
Lubricants which do not have both, the engine oil certi-
fication mark and the correct SAE viscosity grade num-
ber should not be used.
Engine Oil Viscosity (SAE Grade)—3.3/3.8 Liter
Engines
SAE 5W-20 engine oil is recommended for all operating
temperatures. This engine oil improves low temperature
starting and vehicle fuel economy. Refer to your engine
oil filler cap for the recommended engine oil viscosity for
your vehicle.
For information on engine oil filler cap location, refer to
the Engine Compartment illustration in this section.
Lubricants which do not have both, the engine oil certi-
fication mark and the correct SAE viscosity grade num-
ber should not be used.
382 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 have the correct SAE
viscosity grade. Follow the maintenance 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—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 383
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Belts should be inspected for evidence of cuts, cracks, or
glazing, and replaced if there is indication of damage
which could result in belt failure. If adjustment is re-
quired, the belts must be adjusted according to the
specifications and procedures described in the Service
Manual. Low generator belt tension can cause battery
failure. A special tool is required to properly measure
tension and to restore belt tension to factory specifica-
tions.
Also check belt routing to make sure there is no interfer-
ence between the belts and other engine components.
Spark Plugs
Spark plugs must fire properly to assure engine perfor-
mance and emission control. New plugs should be in-
stalled at the specified mileage. The entire set should be
replaced if there is any malfunction due to a faulty sparkplug, malfunctioning spark plugs can damage the cata-
lytic converter. For proper type of replacement spark
plugs, refer to the“Vehicle Emission Control Informa-
tion”label in the engine compartment.
Engine Air Cleaner Filter
Under normal driving conditions, replace the air filter at
the intervals shown on Schedule“A”. If, however, you
drive the vehicle frequently under dusty or severe con-
ditions, the filter element should be inspected periodi-
cally and replaced if necessary at the intervals shown on
Schedule“B”.
384 MAINTAINING YOUR VEHICLE

WARNING!
The air cleaner can provide a measure of protection
in the case of engine backfire. Do not remove the air
cleaner unless such removal is necessary for repair or
maintenance. Make sure that no one is near the
engine compartment before starting the vehicle with
the air cleaner removed. Failure to do so can result in
serious personal injury.
Catalytic Converter
The catalytic converter requires the use of unleaded fuel
only. Leaded gasoline will destroy the effectiveness of the
catalyst as an emission control device.Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.
CAUTION!
Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition. In
the event of engine malfunction, particularly involv-
ing engine misfire or other apparent loss of perfor-
mance, have your vehicle serviced promptly. Contin-
ued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and the
vehicle.
MAINTAINING YOUR VEHICLE 385
7

NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your ex-
haust system. Do not park or operate your vehicle in
areas where your exhaust system can contact any-
thing that can burn.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut off and thevehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer’s specifications, should be ob-
tained immediately.
To minimize the possibility of catalyst damage:
•Do not shut off the engine or interrupt the ignition
when the transmission is in gear and the vehicle is in
motion.
•Do not try to start engine by pushing or towing the
vehicle.
•Do not idle the engine with any spark plug wires
disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.
386 MAINTAINING YOUR VEHICLE

frame with the direction of airflow (away from the
blower motor and towards the center of the car).
Refer to the“Maintenance Schedules”section of this
manual for the recommended air conditioning filter
replacement intervals.
Power Steering—Fluid Check
Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are
apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.
WARNING!
Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturers recommended
power steering fluid.
If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Recommended Fluids, Lubricants, and
Genuine Parts for correct fluid type.
Front Suspension Ball Joints
The front suspension ball joints are permanently sealed.
No regular maintenance is required for these compo-
nents.
390 MAINTAINING YOUR VEHICLE

The external lock cylinders should be lubricated twice a
year, preferably in the fall and spring. Apply a small
amount of a high quality lubricant such as MoparLock
Cylinder Lubricant directly into the lock cylinder.
Windshield Wiper Blades
The rubber edges of the wiper blades and the windshield
should be cleaned periodically with a sponge or soft cloth
and a mild nonabrasive cleaner. This will remove accu-
mulations of salt or road film.
Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield.
Avoid using the wiper blades to remove frost or ice from
the windshield. Keep the blade rubber out of contact with
petroleum products such as engine oil, gasoline, etc.
Windshield and Rear Window Washers
The fluid reservoir for the windshield washers and the
rear window washer is shared. It is located in the engine
compartment and should be checked for fluid level at
regular intervals. Fill the reservoir with windshield
washer solvent (not radiator antifreeze) and operate the
system for a few seconds to flush out the residual water.
The washer fluid reservoir will hold a full gallon of fluid
when the Low Washer Fluid Light illuminates.
392 MAINTAINING YOUR VEHICLE

Exhaust System
The best protection against carbon monoxide entry into
the vehicle body is a properly maintained engine exhaust
system.
Whenever a change is noticed in the sound of the exhaust
system, when exhaust fumes can be detected inside thevehicle, or when the underside or rear of the vehicle is
damaged, have a competent mechanic inspect the com-
plete exhaust system and adjacent body areas for broken,
damaged, deteriorated, or mispositioned parts. Open
seams or loose connections could permit exhaust fumes
to seep into the passenger compartment. In addition,
inspect the exhaust system each time the vehicle is raised
for lubrication or oil change. Replace as required.
WARNING!
Exhaust gases can injure or kill. They contain carbon
monoxide (CO) which is colorless and odorless.
Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, fol-
low the preceding safety tips.Washer Fluid Reservoir
MAINTAINING YOUR VEHICLE 393
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