brake DODGE CARAVAN 2007 4.G Service Manual

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.
442 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.
444 MAINTAINING YOUR VEHICLE

•If your vehicle is damaged due to an accident or
similar cause which destroys the paint and protective
coating, have your vehicle repaired as soon as pos-
sible. The cost of such repairs is considered the respon-
sibility of the owner.
•If you carry special cargo such as chemicals, fertilizers,
de-icer salt, etc., be sure that such materials are well
packaged and sealed.
•If a lot of driving is done on gravel roads, consider
mud or stone shields behind each wheel.
•Use Mopar touch up paint on scratches as soon as
possible. Your dealer has touch up paint to match the
color of your vehicle.
Wheel and Wheel Trim Care
All wheels and wheel trim, especially aluminum and
chrome plated wheels should be cleaned regularly with a
mild soap and water to prevent corrosion. To remove heavy soil and/or excessive brake dust, use Mopar

Wheel Cleaner (05066247AB) or equivalent or select a
nonabrasive, non-acidic cleaner. Do not use scouring
pads, steel wool, a bristle brush, or metal polishes. Only
Mopar  or equivalent is recommended. Do not use oven
cleaner. Avoid automatic car washes that use acidic
solutions or harsh brushes that may damage the wheels’
protective finish.
Interior Care
Use Mopar Total Clean to clean fabric upholstery and
carpeting.
Interior Trim should be cleaned starting with a damp
cloth, a damp cloth with Mopar Total Clean, then Mopar
Spot & Stain Remover if absolutely necessary. Do not use
harsh cleaners or Armorall. Use Mopar Total Clean to
clean vinyl upholstery
Mopar Total Clean is specifically recommended for
leather upholstery.
448 MAINTAINING YOUR VEHICLE

FUSES — INTEGRATED POWER MODULE
An Integrated Power Module (IPM) located in the engine
compartment near the battery. This center contains car-
tridge fuses and mini fuses. A label that identifies each
component may be printed on the inside of the cover.
Refer to the graphic below for FUSES/IPM location.Cavity Cartridge Fuse Description
F4 30 Amp Pink Front Wipers
F9 40 Amp Green Anti-Lock Brake System
(ABS) Pump
F10 40 Amp Green Front Blower
F13 40 Amp Green Electronic Back Light (EBL)
F19 40 Amp Green Body Control Module
(BCM) Feed 1
F20 30 Amp Pink Central Amplifier
F22 30 Amp Pink Seats
F27 40 Amp Green Radiator Fan
Integrated Power module (IPM)
452 MAINTAINING YOUR VEHICLE

Cavity Mini Fuse Description
F21 25 Amp Natural Anti-Lock Brake System
(ABS) Module
F23 10 Amp Red Ignition Switch
F24 20 Amp Yel- low Hazard
F26 20 Amp Yel- low Stop Lamp
F33 15 Amp Blue Front/Rear Washer 20 Amp Yel-
low Spare (IOD)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.
454 MAINTAINING YOUR VEHICLE

Chassis
Component Fluids, Lubricants and Genuine Parts.
Automatic Transmission Mopar ATF+4 Automatic Transmission Fluid.
Brake Master Cylinder Mopar DOT 3, SAE J1703 should be used. If DOT 3, SAE J1703 brake
fluid is not available, then DOT 4 is acceptable. Use only recommended
brake fluids.
Power Steering Reservoir Mopar ATF+4 Automatic Transmission Fluid.
MAINTAINING YOUR VEHICLE 463
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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, power steering and transmission and
add as needed.
•Check all lights and all other electrical items for correct
operation. At Each Oil Change
•Change the engine oil filter.
•Inspect the exhaust system.
•Inspect the brake hoses.
•Inspect the CV joints and front suspension compo-
nents.
•Check the automatic transmission fluid level.
•Check the coolant level, hoses, and clamps.
468 MAINTENANCE SCHEDULES
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Miles 3, 000 6, 000 9, 000 12, 000 15, 000 18, 000
(Kilometers) (5 000 ) (10 000 ) (15 000) (20 000) (25 000) (30 000)
Change engine oil and engine oil filter. XXXXX X
Rotate Tires XX X
Inspect the brake linings. XX
Inspect the engine air cleaner filter, replace if
necessary. XXXX X
Replace the engine air cleaner filter. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines. X
Inspect the generator belt on 2.4 liter engines,
replace if necessary. X
Replace the air conditioning filter. X
470 SCHEDULE “B”
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Miles 21, 000 24, 000 27, 000 30, 000 33, 000 36, 000
(Kilometers) (35 000) (40 000) (45 000) (50 000) (55 000) (60 000)
Change engine oil and engine oil filter. XXXXX X
Rotate Tires XX X
Inspect the brake linings. XX
Inspect the engine air cleaner filter, replace if
necessary. XXX X X
Replace the engine air cleaner filter. X
Replace the spark plugs 2.4 liter engines. X
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines. X
Inspect the generator belt on 2.4 liter engines,
replace if necessary. X
Inspect the PCV valveand replace as neces-
sary. X
Replace the air conditioning filter. XX
SCHEDULE “B” 471
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Miles 39, 000 42, 000 45, 000 48, 000 51, 000 54, 000
(Kilometers) (65 000) (70 000) (75 000) (80 000) (85 000) (90 000)
Change engine oil and engine oil filter. XXXXX X
Rotate Tires XX X
Inspect the brake linings. XX
Inspect the engine air cleaner filter, replace if
necessary. XX XX X
Replace the engine air cleaner filter. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines. X
Inspect the generator belt on 2.4 liter engines,
replace if necessary. X
Replace the air conditioning filter. X
472 SCHEDULE “B”
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