engine DODGE CARAVAN 2009 Repair Manual

4.0L Gasoline Engine
This engine is designed to meet all emis-
sions regulations and provide satisfactory
fuel economy and performance when us-
ing high-quality unleaded gasoline having
an octane range of 87 to 89. The manufac-
turer recommends the use of 89 octane for
optimum performance. The use of premium gasoline is
not recommended. Under normal conditions, the use of
premium gasoline will not provide a benefit over high-
quality regular and mid-grade gasolines, and in some
circumstances may result in poorer performance.
Light spark knock at low engine speeds is not harmful to
your engine. However, continued heavy spark knock at
high speeds can cause damage and immediate service is
required.Poor quality gasoline can cause problems such as hard
starting, stalling and hesitations. If you experience these
symptoms, try another brand of “regular” gasoline be-
fore considering service for the vehicle.
Over 40 automobile manufacturers around the world
have issued and endorsed consistent gasoline specifica-
tions (the World Wide Fuel Charter, WWFC) to define
fuel properties necessary to deliver enhanced emissions,
engine performance, and durability for your vehicle. The
manufacturer recommends the use of gasolines that meet
the WWFC specifications if they are available.
Reformulated Gasoline
Many areas of the country require the use of cleaner
burning gasoline referred to as “Reformulated Gasoline”.
Reformulated gasolines contain oxygenates, and are spe-
cifically blended to reduce vehicle emissions and im-
prove air quality.
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The manufacturer supports the use of reformulated gaso-
lines. Properly blended reformulated gasolines will pro-
vide excellent performance and durability of engine and
fuel system components.
Gasoline/Oxygenate Blends
Some fuel suppliers blend unleaded gasoline with oxy-
genates such as 10% ethanol, MTBE, and ETBE. Oxygen-
ates are required in some areas of the country during the
winter months to reduce carbon monoxide emissions.
Fuels blended with these oxygenates may be used in
your vehicle.
CAUTION!
DO NOT use gasolines containing Methanol or E85
Ethanol. Use of these blends may result in starting
and driveability problems and may damage critical
fuel system components.Problems that result from using methanol/gasoline or
E85 Ethanol blends are not the responsibility of the
manufacturer. While MTBE is an oxygenate made from
Methanol, it does not have the negative effects of
Methanol.
E-85 Usage In Non-Flex Fuel Vehicles
Non-FFV vehicles are compatible with gasoline contain-
ing 10% ethanol (E10). Gasoline with higher ethanol
content may void the vehicle’s warranty.
If a Non-FFV vehicle is inadvertently fueled with E-85
fuel, the engine will have some or all of these symptoms:
•operate in a lean mode
•OBD II “Malfunction Indicator Light” on
•poor engine performance
•poor cold start and cold drivability
•increased risk for fuel system component corrosion
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To fix a Non-FFV vehicle inadvertently fueled once with
E-85 perform the following:
•drain the fuel tank (see your authorized dealer)
•change the engine oil and oil filter
•disconnect and reconnect the battery to reset the
engine controller memory
More extensive repairs will be required for prolonged
exposure to E-85 fuel.
MMT In Gasoline
MMT is a manganese containing metallic additive that is
blended into some gasoline to increase octane. Gasoline
blended with MMT provides no performance advantage
beyond gasoline of the same octane number without
MMT. Gasoline blended with MMT reduces spark plug
life and reduces emission system performance in some
vehicles. The manufacturer recommends that gasoline
without MMT be used in your vehicle. The MMT contentof gasoline may not be indicated on the gasoline pump,
therefore, you should ask your gasoline retailer whether
the gasoline contains MMT.
It is even more important to look for gasolines without
MMT in Canada, because MMT can be used at levels
higher than those allowed in the United States.
MMT is prohibited in Federal and California reformu-
lated gasolines.
Materials Added to Fuel
All gasoline sold in the United States is required to
contain effective detergent additives. Use of additional
detergents or other additives are not needed under
normal conditions and would result in additional cost.
Therefore you should not have to add anything to the
fuel.
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Fuel System Cautions
CAUTION!
Follow these guidelines to maintain your vehicle’s
performance:
•The use of leaded gas is prohibited by Federal law.
Using leaded gasoline can impair engine performance
and damage the emission control system.
•An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your authorized dealer for service assistance.
•The use of fuel additives which are now being sold as
octane enhancers is not recommended. Most of these
products contain high concentrations of methanol.Fuel system damage or vehicle performance problems
resulting from the use of such fuels or additives is not
the responsibility of the manufacturer.
NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
Carbon Monoxide Warnings
WARNING!
Carbon monoxide (CO) in exhaust gases is deadly.
•To prevent carbon monoxide poisoning DO NOT
inhale exhaust gases. They contain carbon monox-
ide, a colorless and odorless gas which can kill.
(Continued)
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WARNING! (Continued)
•NEVER run the engine in a closed area, such as a
garage, and NEVER sit in a parked vehicle with
the engine running for an extended period. If the
vehicle is stopped in an open area with the engine
running for more than a short period, adjust the
ventilation system to force fresh, outside air into
the vehicle.
•Guard against carbon monoxide with proper
maintenance. Have the exhaust system inspected
every time the vehicle is raised. Have any abnor-
mal conditions repaired promptly. Until repaired,
drive with all side windows fully open.
•Keep the liftgate closed when driving your vehicle
to prevent carbon monoxide and other poisonous
exhaust gases from entering the vehicle.
FLEXIBLE FUEL — 3.3L ENGINES ONLY
E-85 General Information
The information in this section is for Flexible Fuel Ve-
hicles (FFV) only. These vehicles can be identified by the
unique fuel filler door label that states:Ethanol (E-85) or
Unleaded Gasoline Only.This section only covers those
subjects that are unique to these vehicles. Please refer to
the other sections of this manual for information on
features that are common between Flexible Fuel and
gasoline only powered vehicles.
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WARNING!
Ethanol vapors are extremely flammable and could
cause serious personal injury. Never have any smok-
ing materials lit in or near the vehicle when remov-
ing the fuel filler tube cap (gas cap) or filling the
tank. Do not use E-85 as a cleaning agent and never
use it near an open flame.
Fuel Requirements
If your vehicle is E-85 compatible, it will operate on
unleaded gasoline with an octane rating of 87, or E-85
fuel, or any mixture of these two fuels.
For best results, a refueling pattern that avoids alternat-
ing between E-85 and unleaded gasoline is recom-
mended.
When you do switch fuel types, it is recommended that:
•you do not add less than 5 gal (19 L) when refueling
•you drive the vehicle immediately after refueling for at
least 5 miles (8 km)
Observing these precautions will avoid possible hard
starting and/or significant deterioration in drivability
during warm up.
NOTE:The characteristics of E-85 fuel require season-
ally adjusted fuel (ASTM D5798) for optimum engine
performance. With non-seasonally adjusted E-85 fuel,
you may experience hard starting and rough idle follow-
ing start-up, even if the above recommendations are
followed, especially when the ambient temperature is
below 32°F (0°C).
Starting
The characteristics of E-85 fuel make it unsuitable for use
when ambient temperatures fall below 0°F (-18°C). In the
range of 0°F (-18°C) to 32°F (0°C), you may experience an
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increase in the time it takes for your engine to start and a
deterioration in drivability (sags and/or hesitations) un-
til the engine is fully warmed up.
NOTE:Use of the engine block heater (if equipped) is
beneficial for E-85 startability when the ambient tempera-
ture is less than 32°F (0°C).
Selection Of Engine Oil For Flexible Fuel Vehicles
(FFV) E-85 and Gasoline Vehicles
FFV vehicles operated on E85 require specially formu-
lated engine oils. These special requirements are included
in MOPARengine oils, and in equivalent oils meeting
Chrysler Specification MS-6395. The manufacturer only
recommends engine oils that are API Certified and meet
the requirements of Material Standard MS-6395. MS-6395
contains additional requirements, developed during ex-
tensive fleet testing, to provide additional protection to
Chrysler LLC engines. Use MOPARor an equivalent oil
meeting the specification MS-6395.
Cruising Range
Because E-85 fuel contains less energy per gallon than
gasoline, you will experience an increase in fuel con-
sumption. You can expect your MPG and your driving
range to decrease by about 30% compared to gasoline
operation.
Replacement Parts
Many components in your Flexible Fuel Vehicle (FFV) are
designed to be compatible with ethanol. Always be sure
that your vehicle is serviced with correct ethanol com-
patible parts.
CAUTION!
Replacing fuel system components with non-ethanol
compatible components can damage your vehicle.
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WARNING!
•Never have any smoking materials lit in or near
the vehicle when the gas cap is removed or the
tank filled.
•Never add fuel when the engine is running. This is
in violation of most state and federal fire regula-
tions and will cause the malfunction indicator
light to turn on.
NOTE:
•Tighten the fuel filler cap until you hear a “clicking”
sound. This is an indication that the fuel filler cap is
properly tightened.
•If the gas cap is not tightened properly, the Malfunc-
tion Indicator Light may come on. Be sure the gas cap
is tightened every time the vehicle is refueled.
WARNING!
A fire may result if gasoline is pumped into a
portable container that is inside of a vehicle. You
could be burned. Always place gas containers on the
ground while filling.
Loose Fuel Filler Cap Message
If thegASCAPmessage is displayed in the instrument
cluster, this signifies a leak or change in the evaporative
system is detected. Sometimes this is the result of a
loosely fitting (or possibly damaged) filler cap. Tighten
the fuel filler cap properly and press the odometer reset
button to turn thegASCAPmessage off.
Make sure that the fuel filler cap is tightened each time
the vehicle is refueled.
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Trailer Towing Weights (Maximum Trailer Weight Ratings)
The following chart provides the maximum trailer weight ratings towable for your given drivetrain.
Engine/TransaxleGCWR (Gross
Combined Wt.
Rating)Frontal Area Max. GTW (Gross Trailer Wt.) Max. Tongue Wt.
3.3L, 3.8L and
4.0L/Automatic7,000 lbs
(3 175 kg)22 sq ft (2.0 sq m)Up to 2 persons & Luggage
1,800 lbs (816 kg)180 lbs (82 kg)
7,000 lbs
(3 175 kg)22 sq ft (2.0 sq m)3 to 5 persons & Luggage 1,350 lbs
(612 kg)135 lbs (61 kg)
7,000 lbs
(3 175 kg)22 sq ft (2.0 sq m)6 to 7 persons & Luggage 1,000 lbs
(454 kg)100 lbs (45 kg)
3.8L and 4.0L/
Automatic (with
Tow Package)9,000 lbs
(4 082 kg)40 sq ft (3.72 sq m)Up to 2 persons & Luggage
3,800 lbs (1 723 kg)*380 lbs (172 kg)
9,000 lbs
(4 082 kg)40 sq ft (3.72 sq m)3 to 5 persons & Luggage 3,350 lbs
(1 519 kg)*335 lbs (152 kg)
9,000 lbs
(4 082 kg)40 sq ft (3.72 sq m)6 to 7 persons & Luggage 3,000 lbs
(1 360 kg)*300 lbs (136 kg)
* For vehicles equipped with Fold-in-Floor seating, the Gross Trailer Weight must be reduced by 100 lbs (45 kg). Refer
to local laws for maximum trailer towing speeds.
NOTE: The trailer tongue weight must be considered as part of the combined weight of occupants and cargo, and
should never exceed the weight referenced on the Tire and Loading Information placard. Refer to Tire–Safety Infor-
mation in this section of the manual.
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WARNING! (Continued)
Make certain that the load is secured in the trailer
and will not shift during travel. When trailering
cargo that is not fully secured, dynamic load shifts
can occur that may be difficult for the driver to
control. You could lose control of your vehicle and
have an accident.
•When hauling cargo or towing a trailer, do not over-
load your vehicle or trailer. Overloading can cause a
loss of control, poor performance or damage to brakes,
axle, engine, transaxle, steering, suspension, chassis
structure or tires.
•Safety chains must always be used between your
vehicle and trailer. Always connect the chains to the
frame or hook retainers of the vehicle hitch. Cross the
chains under the trailer tongue and allow enough
slack for turning corners.
•Vehicles with trailers should not be parked on a grade.
When parking, apply the parking brake on the tow
vehicle. Put the tow vehicle automatic transmission in
PARK. Always, block orchockthe trailer wheels.
•GCWR must not be exceeded.
•Total weight must be distributed between the tow
vehicle and the trailer such that the following four
ratings are not exceeded:
1. GVWR
2. GTW
3. GAWR
4. Trailer tongue weight rating for that trailer hitch.
(This requirement may limit the ability to always
achieve the 10% to 15% range of trailer tongue weight
as a percentage of total trailer weight.)
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