service DODGE CARAVAN 2009 Workshop Manual

WARNING!
Exhaust gases can injure or kill. They contain carbon
monoxide (CO) which is colorless and odorless.
Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, refer
to “Exhaust Gas” in the Safety Tips section of this
manual.
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.
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WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut OFF and the
vehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer’s specifications, should be ob-
tained immediately.To minimize the possibility of catalyst damage:•Do not shut OFF the engine or interrupt the ignition
when the transaxle is in gear and the vehicle is in
motion.
•Do not try to start the engine by pushing or towing the
vehicle.
•Do not idle the engine with any spark plug wires
disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.
Maintenance-Free Battery
The top of the maintenance-free battery is permanently
sealed. You will never have to add water, nor is periodic
maintenance required.
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Air Conditioner Maintenance
For best possible performance, your air conditioner
should be checked and serviced by an authorized dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a system
performance check. Drive belt tension should also be
checked at this time.
WARNING!
•Use only refrigerants and compressor lubricants
approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer to
Section 3 of the Warranty Information book for
further warranty information.
(Continued)
WARNING! (Continued)
•The air conditioning system contains refrigerant
under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.
Refrigerant Recovery and Recycling
R-134a air conditioning refrigerant is a hydrofluoro-
carbon (HFC) that is endorsed by the Environmental
Protection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by an authorized dealer, or other
authorized service facility, using recovery and recycling
equipment.
NOTE:Use only manufacturer-approved A/C System
Sealers, Stop Leak Products, Seal Conditioners, Compres-
sor Oil, or Refrigerants.
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attention should also be given to hood latching compo-
nents to insure proper function. When performing other
underhood services, the hood latch, release mechanism
and safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated twice a
year, preferably in the Fall and Spring. Apply a small
amount of a high quality lubricant such as MOPAR
Lock Cylinder Lubricant directly into the lock cylinder.
Windshield Wiper Blades
The rubber edges of the wiper blades and the windshield
should be cleaned periodically with a sponge or soft cloth
and a mild nonabrasive cleaner. This will remove accu-
mulations of salt or road film.
Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield.Avoid using the wiper blades to remove frost or ice from
the windshield. Keep the blade rubber out of contact with
petroleum products such as engine oil, gasoline, etc.
Windshield and Rear Window Washers
The fluid reservoir for the windshield washers and the
rear window washer is shared. It is located in the engine
compartment and should be checked for fluid level at
regular intervals. Fill the reservoir with windshield
washer solvent (not radiator antifreeze) and operate the
system for a few seconds to flush out the residual water.
The washer fluid reservoir will hold a full gallon of fluid
when the Low Washer Fluid Light illuminates.
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WARNING!
•The warning words “DO NOT OPEN HOT” on
the cooling system pressure cap are a safety pre-
caution. Never add engine coolant (antifreeze)
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 en-
gine damage may result.
Disposal of Used Coolant
Used ethylene glycol-based engine coolant (antifreeze) is
a regulated substance requiring proper disposal. Check
with your local authorities to determine the disposalrules for your community. To prevent ingestion by ani-
mals or children do not store ethylene glycol-based
engine coolant (antifreeze) 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 engine coolant (antifreeze) 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
engine coolant (antifreeze) freeze point or replacing en-
gine coolant (antifreeze). Advise your service attendant
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•Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, also keep the front of
the condenser clean also.
•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.
Brakes
In order to assure brake system performance, all brake
system components should be inspected periodically.
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.
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.
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.
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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 transaxles are equipped with a conven-
tional filler tube and dipstick. If fluid is added, it should
be added through the filler tube.
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. Useonly the manufacturer’s recommended transmission
fluid. Refer to “Fluids, Lubricants and Genuine Parts” in
this section for the correct fluid type. It is important that
the transmission fluid be maintained at the prescribed
level using the recommended fluid. No chemical flushes
should be used in any transaxle; only the approved
lubricant may be used.
CAUTION!
Using a transmission fluid other than the manufac-
turer’s recommended fluid may cause deterioration
in transaxle shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturer’s recommended fluid will result in
more frequent fluid and filter changes. Refer to
“Fluids, Lubricants and Genuine Parts” in this sec-
tion for the correct fluid type.
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Fluid Level Check — 3.8L and 4.0L Engines with
Six-Speed Automatic Transaxle — 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.
Fluid Level Check — 3.3L Engine with Four-Speed
Automatic Transaxle — If Equipped
The dipstick is located just behind the radiator on the
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 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 fingertips. 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.
4 Speed ATX Diptstick
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FUSES/TIPM
CavityCartridge
FuseMini-
FuseDescription
M33 — 10 Amp
RedNext Generation Con-
troller (NGC), Global
Powertrain Engine
Controller (GPEC)
M34 — 10 Amp
RedPark Assist (PRK
ASST), Heater Venti-
lation, Air Condition-
ing Module (HVAC
MOD), Headlamp
Wash (HDLP WASH),
Compass (COMPAS)
M35 — 10 Amp
RedHeated Mirrors
M36 — 20 Amp
YellowPower Outlet #3
(BATT)
FUSES/TIPM
CavityCartridge
FuseMini-
FuseDescription
M37 — 10 Amp
RedAnti-Lock Brake Sys-
tem (ABS), Electronic
Stability Program
(ESP), Stop Lamp
Switch (STP LP SW),
Fuel Pump Rly Hi
Control
M38 — 25 Amp
NaturalLock/Unlock Motors
(LOCK/UNLOCK
MTRS)
The heated mirrors, lower instrument panel power outlet
and removable floor console, when in the front position
are fused with self-resetting fuses that are only service-
able 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
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steering column. If you experience temporary or perma-
nent 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 do the following:
•Remove the 20 Amp mini-fuse in the Totally Inte-
grated Power Module (TIPM) labeled Ignition-Off
Draw (IOD).
•Or, disconnect the negative cable from the battery.
•Anytime you store your vehicle, or keep it out of
service for two weeks or more, run the air conditioning
system at idle for about five minutes in the fresh air
and high blower setting. This will ensure adequate
system lubrication to minimize the possibility of com-
pressor damage when the system is started again.
REPLACEMENT LIGHT BULBS
LIGHT BULBS — Interior Bulb Number
Center & Rear Dome Light.................. 578
Center & Rear Reading Lights............... 578
Front Door Courtesy Light.................. 578
Front Header Reading Lights — If Equipped..... 578
Instrument Cluster Lights.................PC74
Liftgate Light(s).......................... 578
Overhead Console Reading Lights..........PC579
Removable Console Light — If Equipped....... 194
Visor Vanity Lights....................6501966
NOTE:For lighted switches, see your authorized dealer
for replacement instructions.
All of the interior bulbs are glass wedge base or glass
cartridge types. Aluminum base bulbs are not approved
and should not be used for replacement.
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