DODGE CARAVAN 2008 5.G Owners Manual

WARNING!
²The warning words ªDO NOT OPEN HOTº 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 scald-
ing or injury, do not remove the pressure cap while
the system is hot or under pressure.
²Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or en-
gine damage may result.
Disposal of Used 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 yourcommunity. To prevent ingestion by animals or children
do 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.
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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When additional coolant is needed to maintain the
proper level, it should be added to the coolant bottle. Do
not overfill.
Points To Remember
NOTE:When the vehicle is stopped after a few miles (a
few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high
humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot coolant to
enter the radiator.
If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.
²Do not overfill the coolant recovery bottle.
²Check coolant freeze point in the radiator and in the
coolant recovery bottle. If antifreeze needs to be
added, contents of coolant recovery bottle must also be
protected against freezing.
²If frequent coolant additions are required, or if the
level in the coolant recovery bottle does not drop when
the engine cools, the cooling system should be pres-
sure tested for leaks.
²Maintain coolant concentration at 50% HOAT engine
coolant (minimum) and distilled water for proper
corrosion protection of your engine which contains
aluminum components.
²Make sure that the radiator and coolant recovery
bottle overflow hoses are not kinked or obstructed.
²Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean, also.
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²Do 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.
Ensure 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.FUEL SYSTEM CONNECTIONS
The Electronic Fuel Injection high-pressure fuel system's
hoses and quick connect fittings have unique material
characteristics that provide adequate sealing and resist
attack by deteriorated gasoline.
You are urged to use only the manufacture specified
hoses with quick connect fittings, or their equivalent in
material and specification, in any fuel system servicing. It
is mandatory to replace any damaged hoses or quick
connect fittings that have been removed during service.
Care should be taken in installing quick connect fittings
to ensure they are properly installed and fully connected.
See your authorized dealer for service.
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7

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.
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.
Ensure 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.
462 MAINTAINING YOUR VEHICLE

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
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 Ð 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
ªFULLº 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 manufacturer's recommended brake fluid, refer
to Fluids, Lubricants and Genuine Parts for correct fluid
type.
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WARNING!
²Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
²Use of a brake fluid that has a lower initial boiling
point than the recommended MOPARtDOT 3
product or a brake fluid that is unidentified as to
FMVSS specification may result in sudden brake
failure during hard prolonged braking. You could
have an accident.
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 Ð all brake seal components could be
damaged causing partial or complete brake failure.
AUTOMATIC TRANSAXLE
The automatic transaxle and differential assembly are
contained within a single housing.
The fluid level in the automatic transaxle should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transaxle and the fluid.
All Four±Speed automatic transaxles are equipped with a
conventional filler tube and dipstick. If fluid is added, it
should be added through the filler tube.
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All six speed transaxles are equipped with a capped
dipstick tube, it is sealed and should not be tampered
with. Your authorized dealer has the necessary tools to
ensure that the fluid level is set properly.
Selection of Lubricant
It is important that the proper lubricant is used in the
transaxle to assure optimum transaxle performance. Use
only manufacturer 's recommended transaxle fluid; refer
to Fluids, Lubricants and Genuine Parts for correct fluid
type. It is important that the transaxle fluid be main-
tained at the prescribed level using the recommended
fluid. No chemical flushes should be used in any trans-
axle; only the approved lubricant may be used.
CAUTION!
Using a transaxle fluid other than the manufacturer's
recommended fluid may cause deterioration in trans-
axle shift quality and/or torque converter shudder.
Using a transaxle fluid other than the manufacturer's
recommended fluid will result in more frequent
fluid and filter changes. Refer to Fluids, Lubricants
and Genuine Parts for correct fluid type.
Fluid Level Check Ð 3.8L and 4.0L Engines with
Six-Speed Automatic Transaxle Ð If Equipped
The Six-Speed automatic transaxle is a sealed unit and
has no dipstick. See your authorized dealer to have the
transaxle fluid checked or serviced.
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Fluid Level Check Ð 3.3L Engine with Four-Speed
Automatic Transaxle Ð If Equipped
The dipstick is located just behind the radiator, lower
right side.
To properly check the automatic transaxle 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 lever momentarily in each gear
position ending with the lever in PARK. Wipe the area
around the dipstick clean to eliminate the possibility of
dirt entering the transaxle.
5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180ÉF (82ÉC), 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 80ÉF (27ÉC).
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 ªHOTº (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 ªCOLDº.
4 Speed ATX Diptstick
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If the fluid level indicates low, add sufficient fluid to
bring to the proper level.
CAUTION!
Do not overfill. Dirt and water in the transaxle can
cause serious damage. To prevent dirt and water from
entering the transaxle after checking or replenishing
fluid, make certain that the dipstick cap is reseated
properly.
Fluid and Filter Changes
Refer to the ªMaintenance Scheduleº in Section 8 of this
manual for the recommended transaxle fluid and filter
change intervals.
If the transaxle is disassembled for any reason, the fluid
and filter should be changed.
Special Additives
Automatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transaxle. The only exception to this policy is
the use of special dyes to aid in detecting fluid leaks. In
addition, avoid using transaxle sealers as they may
adversely affect seals.
FRONT AND REAR WHEEL BEARINGS
Front and rear wheel bearings are permanently sealed.
No regular maintenance is required for these compo-
nents.
APPEARANCE CARE AND PROTECTION FROM
CORROSION
Protection of Body and Paint from Corrosion
Vehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on
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trees and road surfaces during other seasons, are highly
corrosive to the metal in your vehicle. Outside parking,
which exposes your vehicle to airborne contaminants,
road surfaces on which the vehicle is operated, extreme
hot or cold weather and other extreme conditions will
have an adverse effect on paint, metal trim, and under-
body protection.
The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.
What Causes Corrosion?
Corrosion is the result of deterioration or removal of
paint and protective coatings from your vehicle.
The most common causes are:
²Road salt, dirt and moisture accumulation
²Stone and gravel impact
²Insects, tree sap and tar
²Salt in the air near seacoast localities
²Atmospheric fallout/industrial pollutants
Washing
²
Wash your vehicle regularly. Always wash your ve-
hicle in the shade using MopartCar Wash or a mild
car wash soap, and rinse the panels completely with
clear water.
²If insects, tar or other similar deposits have accumu-
lated on your vehicle, use MopartSuper Kleen Bug
and Tar Remover to remove.
²Use MopartCleaner Wax to remove road film, stains
and to protect your paint finish. Take care never to
scratch the paint.
468 MAINTAINING YOUR VEHICLE