service DODGE CARAVAN 2006 4.G Service Manual

WARNING!
Because the front wheels drive and steer the vehicle,
it is important that you do not exceed the maximum
front or rear GAWR. A dangerous driving condition
can result if either rating is exceeded. You could lose
control of the vehicle and have an accident.
Overloading
The load carrying components (axle, springs, tires,
wheels, etc.) of your vehicle will provide satisfactory
service as long as you do not exceed the GVWR and front
and rear GAWR.
The best way to figure out the total weight of your
vehicle is to weigh it when it is fully loaded and ready for
operation. Weigh it on a commercial scale to insure that it
is not over the GVWR.Figure out the weight on the front and rear of the vehicle
separately. It is important that you distribute the load
evenly over the front and rear axles.
Overloading can cause potential safety hazards and
shorten useful service life. Heavier axles or suspension
components do not necessarily increase the vehicle’s
GVWR.
Loading
To load your vehicle properly, first figure out its empty
weight, axle by axle and side by side. Store heavier items
down low and be sure you distribute their weight as
evenly as possible. Stow all loose items securely before
driving. If weighing the loaded vehicle shows that you
have exceeded either GAWR, but the total load is within
the specified GVWR, you must redistribute the weight.
Improper weight distribution can have an adverse effect
on the way your vehicle steers and handles and the way
the brakes operate.
STARTING AND OPERATING 349
5

IF YOUR ENGINE OVERHEATS
In any of the following situations, you can reduce the
potential for overheating by taking the appropriate ac-
tion.
•On the highways—Slow down.
•In city traffic—While stopped, put transaxle in
neutral, but do not increase engine idle speed.
NOTE:There are steps that you can take to slow down
an impending overheat condition. If your air conditioner
is on, turn it off. The air conditioning system adds heat to
the engine cooling system and turning off the A/C
removes this heat. You can also turn the Temperature
control to maximum heat, the Mode control to floor, and
the fan control to High. This allows the heater core to act
as a supplement to the radiator and aids in removing heat
from the engine cooling system.
CAUTION!
Driving with a hot cooling system could damage
your vehicle. If temperature gauge reads“H”, pull
over and stop the vehicle. Idle the vehicle with the
air conditioner turned off until the pointer drops
back into the normal range. If the pointer remains on
the“H”, turn the engine off immediately, and call for
service.
WHAT TO DO IN EMERGENCIES 367
6

WARNING!
A hot engine cooling system is dangerous. You or
others could be badly burned by steam or boiling
coolant. You may want to call a service center if your
vehicle overheats. If you decide to look under the
hood yourself, see Section 7, Maintenance, of this
manual. Follow the warnings under the Cooling
System Pressure Cap paragraph.
JACKING AND TIRE CHANGING
WARNING!
•Getting under a jacked-up vehicle is dangerous. The
vehicle could slip off the jack and fall on you. You
could be crushed. Never get any part of your body
under a vehicle that is on a jack. If you need to get
under a raised vehicle, take it to a service center
where it can be raised on a lift.
•The jack is designed to use as a tool for changing
tires only. The jack should not be used to lift the
vehicle for service purposes. The vehicle should be
jacked on a firm level surface only. Avoid ice or
slippery areas.
•For vehicles equipped with Stow’n Go seating, if it
is necessary to retrieve the spare tire from under the
vehicle on the side of the vehicle close to moving
traffic. Pull far enough off the road to avoid the
danger of being hit.
368 WHAT TO DO IN EMERGENCIES

CAUTION!
The winch mechanism is designed for use with the
winch“T”handle only. Use of an air wrench or other
power tools is not recommended and can damage the
winch.
3. Assemble the winch handle extensions to form the
Spare Tire Hook and pull the compact spare tire/cover
assembly from under the vehicle.
WARNING!
Getting under a jacked-up vehicle is dangerous. The
vehicle could slip off the jack and fall on you. You
could be crushed. Never get any part of your body
under a vehicle that is on a jack. If you need to get
under a raised vehicle, take it to a service center
where it can be raised on a lift.
WHAT TO DO IN EMERGENCIES 373
6

10. Lower the vehicle by turning the jack screw to the
left.
11. Finish tightening the lug nuts. Push down on the
wrench while tightening for increased leverage. Alternate
lug nuts until each nut has been tightened twice. Correct
wheel nut tightness is 130 N·m (95 ft. lbs). If in doubt
about the correct tightness, have them checked with a
torque wrench by your dealer or at a service station.
12. Lower the jack to its fully closed position.
13. Secure the flat tire as follows:
•Place the deflated (flat) tire and compact spare tire
cover assembly in the rear cargo area,have the tire
repaired or replaced as soon as possible.
WARNING!
A loose deflated (flat) tire thrown forward in a
collision or hard stop could injure the occupants in
the vehicle. Have the deflated (flat) tire repaired or
replaced immediately.
CAUTION!
Vehicle damage will occur if the compact spare tire
cover assembly is installed without the compact
spare tire in position. Place the deflated (flat) tire
and compact spare tire cover assembly in the rear
cargo area.
WHAT TO DO IN EMERGENCIES 377
6

NOTE:Do not install the wheel cover on the compact
spare.
Do not use a hammer or force to install the wheel covers.
9. Lower the vehicle by turning the jack screw to the left.
10. Finish tightening the lug nuts. Push down on the
wrench while tightening for increased leverage. Alternate
lug nuts until each nut has been tightened twice. Correct
wheel nut tightness is 130 N·m (95 ft. lbs). If in doubt
about the correct tightness, have them checked with a
torque wrench by your dealer or at a service station.
11. Lower the jack to its fully closed position.WARNING!
A loose tire or jack, thrown forward in a collision or
hard stop could endanger the occupants of the ve-
hicle. Always stow the jack parts and the spare tire in
the places provided.
12. Secure the flat or spare tire as follows:
•If your vehicle is equipped with cast aluminum
wheels, the center cap of the wheel must be re-
moved prior to flat tire stowage. Store the center cap
inside the glove box or other storage compartment.
•Turn the wheel so that the valve stem is down. Slide
the wheel retainer through the center of the wheel
and position it properly across the wheel opening.
386 WHAT TO DO IN EMERGENCIES

MAINTAINING YOUR VEHICLE
CONTENTS

2.4L Engine...........................396

3.3L/3.8L Engines......................397

Onboard Diagnostic System—OBDII........398

Emissions Inspection And Maintenance
Programs............................399

Replacement Parts......................400

Dealer Service.........................400

Maintenance Procedures..................401
▫Engine Oil..........................401▫Engine Oil Filter......................405
▫Drive Belts—Check Condition And Tension . . 405
▫Spark Plugs.........................406
▫Engine Air Cleaner Filter................406
▫Catalytic Converter....................407
▫Maintenance-Free Battery................409
▫Air Conditioner Maintenance.............410
▫Power Steering—Fluid Check............412
▫Front Suspension Ball Joints..............412
7

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.
398 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 399
7

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.
400 MAINTAINING YOUR VEHICLE