service DODGE CARAVAN 2006 4.G Repair Manual

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.
Engine Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine cold, the level of the coolant in the coolant
recovery bottle should be between the ranges indicated
on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.
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•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 coolant performance, poor gas
mileage, and increased emissions.
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.
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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.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.
NOTE:Often, fluid such as oil, power steering fluid,
and brake fluid are used during assembly plant opera-
tions to facilitate the assembly of hoses to couplings.
Therefore, oil wetness at the hose-coupling area is not
necessarily an indication of leakage. Actual dripping of
hot fluid when systems are under pressure (during
vehicle operation), should be noted before hose is re-
placed based on leakage.
NOTE:Inspection of brake hoses should be performed
whenever the brake system is serviced and every engine
oil change. Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If there is any evidence
of cracking, scuffing, or worn spots, the hose should be
422 MAINTAINING YOUR VEHICLE

replaced immediately! Eventual deterioration of the hose
can take place resulting in a possibility of a burst failure.
WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
Master Cylinder—Brake Fluid Level Check
The fluid level in the master cylinder should be checked
when performing underhood services, or immediately if
the brake system warning light indicates system failure.
Clean the top of the master cylinder area before removing
the cap. Add fluid to bring the level up to the top of the
“FULL”mark on the side of the master cylinder reservoir.Overfilling of fluid is not recommended because it may
cause leaking in the system.
Add enough fluid to bring the level up to the require-
ments described on the brake fluid reservoir. With disc
brakes, fluid level can be expected to fall as the brake
pads wear. However, low fluid level may be caused by a
leak and a checkup may be needed.
Use only manufacturers recommended brake fluid, refer
to Fluids, Lubricants and Genuine Parts for correct fluid
type.WARNING!
Use of brake fluid that may have a lower initial
boiling point or unidentified as to specification, may
result in sudden brake failure during hard pro-
longed braking. You could have an accident.
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WARNING!
Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.
CAUTION!
Do not allow petroleum base fluid to contaminate
the brake fluid, all brake seal components could be
damaged causing partial or complete brake failure.
Fuel System Hoses
Electronic Fuel Injection high pressure fuel systems are
designed with hoses which have unique material charac-
teristics to provide adequate sealing and resist attack by
deteriorated gasoline.
Use only the manufacturers specified hoses in any fuel
system servicing. It is mandatory to replace all clamps
that have been loosened or removed during service. Care
should be taken in installing new clamps to insure they
are properly torqued.
Automatic Transmission
The automatic transmission and differential assembly are
contained within a single housing.
All automatic transmissions are equipped with a conven-
tional filler tube and dipstick. If fluid is added, it should
be added through the dipstick hole in the case.
424 MAINTAINING YOUR VEHICLE

Procedure For Checking Fluid Level
The fluid level in the automatic transmission should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transmission and of the fluid.
To properly check the automatic transmission fluid level,
the following procedure must be used:
1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for a
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector momentarily in each gear
position ending with the lever in P (PARK). Wipe the area
around the dipstick clean to eliminate the possibility of
dirt entering the transmission.5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180°F (82°C), which
is the normal operating temperature after the vehicle has
been driven at least 15 miles (24 km). The fluid cannot be
comfortably held between the finger tips. Cold is when
the fluid is below 80°F (27°C).
6. Wipe the dipstick clean and reinsert until seated.
Remove dipstick and note reading.
a. If the fluid is hot, the reading should be in the
crosshatched area marked“HOT”(between the upper
two holes in the dipstick).
b. If the fluid is cold, the fluid level should be between
the lower two holes in the area marked“COLD”.
If the fluid level indicates low, add sufficient fluid to
bring to the proper level.
426 MAINTAINING YOUR VEHICLE

CAUTION!
•When installing the Integrated Power Module
cover, it is important to ensure the cover is prop-
erly positioned and fully latched. Failure to do so
may allow water to get into the Integrated Power
Module, and possibly result in a electrical system
failure.
•When replacing a blown fuse, it is important to
use only a fuse having the correct amperage
rating. The use of a fuse with a rating other than
indicated may result in a dangerous electrical
system overload. If a properly rated fuse contin-
ues to blow, it indicates a problem in the circuit
that must be corrected.
The Heated Mirrors, Lower Instrument Panel Power
Outlet and Removable Floor Console, when in the frontposition are fused with self resetting fuses that are only
serviceable by an authorized dealer. The power seats are
fused by a 30 Amp circuit breaker located under the
driver’s seat. The Power Windows are fused by a 25 Amp
circuit breaker located under the instrument panel near
the steering column. If you experience temporary or
permanent loss of these systems see your authorized
dealer for service.
VEHICLE STORAGE
If you are leaving your vehicle dormant for more than 21
days you may want to take steps to protect your battery.
You may:
•Remove the 20 Amp mini fuse in the Integrated Power
Module labeled Ignition-Off Draw (IOD).
•Or, disconnect the negative cable from the battery.
•Anytime you store your vehicle, or keep it out of
service (i.e. vacation) for two weeks or more, run the
436 MAINTAINING YOUR VEHICLE

EMISSION CONTROL SYSTEM MAINTENANCE
The“Scheduled”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 Schedule“B”. It is for vehicles that are operated
under the conditions that are listed below and at the
beginning of the schedule.
•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.
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•Taxi, police, or delivery service (commercial ser-
vice).
•Off-road or desert operation.
NOTE:Most vehicles are operated under the conditions
listed for ScheduleB.
Second is Schedule“A”. It is for vehicles that are not
operated under any of the conditions listed under Sched-
uleB.
Use the schedule that best describes your driving condi-
tions. Where time and mileage are listed, follow the
interval that occurs first.
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.
At Each Stop for Fuel
•Check the engine oil level about 5 minutes after a fully
warmed engine is shut off. Checking the oil level while
the vehicle is on level ground will improve the accu-
racy of the oil level reading. Add oil only when the
level is at or below the ADD or MIN mark.
•Check the windshield washer solvent and add if
required.
Once a Month
•Check tire pressure and look for unusual wear or
damage.
•Inspect the battery and clean and tighten the terminals
as required.
•Check the fluid levels of coolant reservoir, brake
master cylinder and transmission; add as needed.
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SCHEDULE“B”
Follow schedule“B”if you usually operate your vehicle
under one or more of the following conditions. Change
the automatic transmission fluid and filter every 60,000
miles (96 000 km) if the vehicle is usually operated under
one or more of the conditions marked with an.
•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 ser-
vice).
•Off-road or desert operation.
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