service DODGE CARAVAN 2008 5.G Service Manual

1. Loosen (but do not remove) the wheel lug nuts by
turning them to the left one turn while the wheel is still
on the ground.
2. To remove the compact spare tire/cover assembly,
assemble the winch handle extensions to form a ªT' and
fit the winch ªTº handle over the drive nut. Rotate the
nut to the left until the winch mechanism stops turning
freely. This will allow enough slack in the cable to allow
you to pull the spare tire out from under the vehicle.
CAUTION!
The winch mechanism is designed for use with the
winch ªTº 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 417
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 95 ft lbs (130 N´m). If in doubt
about the correct tightness, have them checked with a
torque wrench by your authorized dealer or at a service
station.
12. 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. Have the deflated (flat) tire
repaired or replaced immediately.13. Place the deflated (flat) tire and compact spare tire
cover assembly in the rear cargo area.Do not stow the
deflated tire in the spare tire location.Have the full
sized tire repaired or replaced as soon as possible.
14. Stow the cable and wheel spacer before driving the
vehicle. Reassemble the winch handle extensions to form
a ªT' and fit the winch ªTº handle over the drive nut.
Rotate the nut to the right until the winch mechanism
clicks at least three times.
15. Stow the jack, jack handle and winch handle tools.
16. Check the compact spare tire pressure as soon as
possible. Correct pressure as required.Wheel Nuts
All wheel nuts should be tightened occasionally to elimi-
nate the possibility of wheel studs being sheared or the
bolt holes in the wheels becoming elongated. This is
especially important during the first few hundred miles
422 WHAT TO DO IN EMERGENCIES

MAINTAINING YOUR VEHICLE
CONTENTS
m3.3L Engine Compartment................434
m3.8L Engine Compartment................435
m4.0L Engine Compartment................436
mOnboard Diagnostic System Ð OBD II........437
NLoose Fuel Filler Cap Message Ð gASCAP . . . 438
mEmissions Inspection And Maintenance
Programs............................438
mReplacement Parts......................440
mAuthorized Dealer Service................440mMaintenance Procedures..................441
NEngine Oil..........................441
NEngine Oil Filter......................444
NDrive Belt...........................445
NSpark Plugs.........................445
NEngine Air Cleaner....................445
NCatalytic Converter....................446
NMaintenance-Free Battery................448
NAir Conditioner Maintenance.............450
7

ONBOARD DIAGNOSTIC SYSTEM Ð 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 ªMalfunction Indicator Light.º 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 authorized dealer for service as
soon as possible.CAUTION!
²Prolonged driving with the ªMalfunction Indica-
tor Lightº 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.
²If the ªMalfunction Indicator Lightº is flashing
while the engine is running, severe catalytic con-
verter damage and power loss will soon occur.
Immediate service is required.
MAINTAINING YOUR VEHICLE 437
7

Loose Fuel Filler Cap Message Ð gASCAP
Should the ªLoose Fuel Filler Capº or ªgASCAPº mes-
sage appear, there may be a problem in the evaporative
system. Before taking the vehicle into an authorized
dealer, check first to see if the fuel filler cap is possibly
loose, improperly installed, or damaged. A loose fuel
filler cap message will be displayed in the instrument
cluster. Tighten the gas cap until a9clicking9sound is
heard. This is an indication that the gas cap is properly
tightened. Press the odometer reset button to turn the
message off. If the problem persists, the message will
appear the next time the vehicle is started. If the problem
is detected twice in a row, the system will turn on the
Malfunction Indicator Light (MIL). Resolving the prob-
lem will turn the MIL light off. Take your vehicle in to an
authorized dealer.
EMISSIONS INSPECTION AND MAINTENANCE
PROGRAMS
In some localities, it may be a legal requirement to pass
an inspection of this vehicle's emissions control system.
Failure to pass could prevent vehicle registration.
For states that require an Inspection and Mainte-
nance (I/M), this check verifies the Malfunction
Indicator Light (MIL) is functioning and is not on
when the engine is running, and that the OBD II system
is ready for testing.
Normally, the OBD II system will be ready. The OBD II
system maynotbe ready if the vehicle was recently
serviced, recently had a dead battery, or a battery replace-
ment. If the OBD II system should be determined not
ready for the I/M test, the vehicle may fail the test.
438 MAINTAINING YOUR VEHICLE

This vehicle has a simple ignition key-actuated test,
which you can use prior to going to the test station. To
check if this vehicle's OBD II system is ready, you must
do the following:
1. Insert the 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 the ignition key to the ON
position, you will see the 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 OFFthe ignition key or start the engine. This means that the
vehicle's OBD II system isnot readyand you should
notproceed 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 the vehicle's OBD II
system isready,and you can proceed to the I/M
station.
If the OBD II system isnot ready,you should see an
authorized dealer or repair facility. If this vehicle was
recently serviced or had a battery failure or replacement,
you may need to do nothing more than drive the vehicle
as you normally would in order for the OBD II system to
update. A recheck with the above test routine may then
indicate that the system is now ready.
Regardless of whether the vehicle's OBD II system is
ready or not ready, if the MIL is illuminated during
normal vehicle operation, you should have the vehicle
MAINTAINING YOUR VEHICLE 439
7

serviced before going to the I/M station. The I/M station
can fail the vehicle because the MIL is on with the engine
running.
REPLACEMENT PARTS
Use of genuine Mopartparts for normal/scheduled
maintenance and repairs is highly recommended to en-
sure the designed performance. Damage or failures
caused by the use of non-Mopartparts for maintenance
and repairs will not be covered by the manufacturer's
warranty.
AUTHORIZED DEALER SERVICE
Your authorized dealer has the qualified service person-
nel, 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 service manuals before
attempting any procedure yourself.NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
WARNING!
You can be badly injured working on or around a
motor vehicle. Only do service work for which you
have the knowledge and the proper equipment. If
you have any doubt about your ability to perform a
service job, take your vehicle to a competent
mechanic.
440 MAINTAINING YOUR VEHICLE

MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.
ENGINE OIL
Checking Oil Level
To assure proper engine lubrication, the engine oil must
be maintained at the correct level. Check the oil level at
regular intervals, such as every fuel stop.
The best time to check the engine oil level is about five
minutes after a fully warmed engine is shut off or before
starting the engine after it has sat overnight.
MAINTAINING YOUR VEHICLE 441
7

Synthetic Engine Oils
You may use synthetic engine oils provided the recom-
mended oil quality requirements are met, and the recom-
mended maintenance intervals for oil and filter changes
are followed.
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 its
performance may be impaired by supplemental addi-
tives.
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 authorized dealer, servicestation, or governmental 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
The manufacturer's 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. MopartEngine Oil Filters are a high quality oil
filter and are recommended.
444 MAINTAINING YOUR VEHICLE

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.
NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
446 MAINTAINING YOUR VEHICLE