fuel DODGE CARAVAN 2010 Service Manual

MAINTAINING YOUR VEHICLE
CONTENTS
Engine Compartment — 3.3/3.8L .......... 431
 Engine Compartment — 4.0L ............. 432
 Onboard Diagnostic System — OBD II ...... 433
▫ Loose Fuel Filler Cap Message ........... 433
 Emissions Inspection And Maintenance
Programs ............................ 434
 Replacement Parts ..................... 436
 Dealer Service ........................ 436 
Maintenance Procedures ................. 436
▫ Engine Oil ......................... 437
▫ Engine Oil Filter ..................... 440
▫ Engine Air Cleaner Filter ............... 440
▫ Exhaust System ..................... 441
▫ Maintenance-Free Battery .............. 443
▫ Air Conditioner Maintenance ............ 444
▫ Body Lubrication .................... 447
▫ Windshield Wiper Blades ............... 447
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ONBOARD DIAGNOSTIC SYSTEM — 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 “Malfunction Indicator Light (MIL).” 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!
•Prolonged driving with the MIL 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 performed.
•If the MIL is flashing while the engine is running,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.
Loose Fuel Filler Cap Message
If the vehicle diagnostic system determines that the fuel
filler cap is loose, improperly installed, or damaged, a
“gASCAP” message will display in the odometer or a
“CHECK GASCAP” message will be displayed in the
Electronic Vehicle Information Center (EVIC). Refer to
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CAUTION!
•Failure to properly maintain your vehicle or per-
form repairs and service when necessary could
result in more costly repairs, damage to other
components or negatively impact vehicle perfor-
mance. Immediately have potential malfunctions
examined by an authorized Chrysler Group LLC
dealership or qualified repair center.
•Your vehicle has been built with improved fluids
that protect the performance and durability of
your vehicle and also allow extended maintenance
intervals. Do not use chemical flushes in these
components as the chemicals can damage your
engine, transmission, power steering or air condi-
tioning. Such damage is not covered by the New
Vehicle Limited Warranty. If a flush is needed
because of component malfunction, use only the
specified fluid for the flushing procedure.
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.
Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Maintain
the oil level between the MIN and MAX markings on the
dipstick. Adding one quart of oil when the reading is at
the MIN mark will result in a MAX reading on these
engines.
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Engine Oil Viscosity (SAE Grade) – 3.3L & 3.8L
Gasoline Engines
SAE 5W-20 engine oil is recommended for all operating
temperatures. This engine oil improves low temperature
starting and vehicle fuel economy. Your engine oil filler
cap also shows the recommended engine oil viscosity for
your vehicle.
For information on engine oil filler cap location, refer to
“Engine Compartment” in “Maintaining Your Vehicle”
for further information.
Lubricants that do not have both the engine oil certifica-
tion mark and the correct SAE viscosity grade number,
should not be used.
Engine Oil Viscosity (SAE Grade) – 4.0L Gasoline
Engines
SAE 10W-30 engine oil is preferred for all operating
temperatures. Your engine oil filler cap also shows the
recommended engine oil viscosity for your vehicle.For information on engine oil filler cap location, refer to
“Engine Compartment” in “Maintaining Your Vehicle”
for further information.
Lubricants that do not have both the engine oil certifica-
tion mark and the correct SAE viscosity grade number,
should not be used.
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 manufacturer strongly recommends against the ad-
dition 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
additives.7
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CAUTION!
•The catalytic converter requires the use of un-
leaded fuel only. Leaded gasoline will destroy the
effectiveness of the catalyst as an emissions con-
trol device and may seriously reduce engine per-
formance and cause serious damage to the engine.
•Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition.
In the event of engine malfunction, particularly
involving engine misfire or other apparent loss of
performance, have your vehicle serviced promptly.
Continued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and
vehicle.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.
NOTE:
Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may suggest severe
and abnormal catalyst overheating. If this occurs, stop
the vehicle, turn off the engine and allow it to cool.
Service, including a tune-up to manufacturer’s specifica-
tions, should be obtained immediately.
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FUSES/TIPM
Cavity Cartridge
Fuse Mini-Fuse Description
J8 40 Amp Green — Power Memory
Seat – If Equipped
J9 40 Amp Green — Partial Zero Emis-
sions Vehicle
Motor/Flex Fuel
J10 30 Amp Pink — Headlamp Wash
Relay/Manifold
Tuning Valve
J11 30 Amp Pink — Power Sliding Door
Module/Anti–Theft
Module Relay Lock
Feed
J13 60 Amp Yellow — Ignition Off Draw
(IOD) – Main
J14 40 Amp Green — Rear Window De-
foggerFUSES/TIPM
Cavity Cartridge
Fuse Mini-Fuse Description
J15 30 Amp Pink — Rear Blower
J17 40 Amp Green — Starter Solenoid
J18 20 Amp Blue — Powertrain
Control Module
Trans Range
J19 60 Amp Yellow — Radiator Fan
J20 30 Amp Pink — Front Wiper LO/HI
J21 20 Amp Blue — Front/Rear Washer
J22 25 Amp Natural — Sunroof Module
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FUSES/TIPM
Cavity Cartridge
Fuse Mini-Fuse Description
M18 — 15 Amp BlueRight Tail/Park/
Run Lamp
M19 — 25 Amp NaturalAutomatic Shut-
down #1 and #2
M20 — 15 Amp BlueInstrument Cluster
Interior Light,
Switch Bank, Steer-
ing Column Mod-
ule, Switch Steering
Wheel
M21 — 20 Amp YellowAutomatic
Shutdown #3
M22 — 10 Amp RedRight Horn
(HI/LOW)
M23 — 10 Amp RedLeft Horn
(HI/LOW)FUSES/TIPM
Cavity Cartridge
Fuse Mini-Fuse Description
M24 — 25 Amp NaturalRear Wiper
M25 — 20 Amp YellowFuel Pump, Diesel
Lift Pump – Export
Only
M26 — 10 Amp RedPower Mirror
Switch, Driver
Window Switch
M27 — 10 Amp RedIgnition Switch,
Wireless Control
Module, Keyless
Entry Module,
Steering Column
Lock
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FUSES/TIPM
Cavity Cartridge
Fuse Mini-Fuse Description
M35 — 10 Amp RedHeated Mirrors
M36 — 20 Amp YellowPower Outlet #3
M37 — 10 Amp RedAntilock Brakes,
Stability Control
System, Stop Lamp
Switch, Fuel Pump
Rly Hi Control
M38 — 25 Amp NaturalDoor Lock/Unlock
Motors, Liftgate
Lock/Unlock
Motors
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
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.
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2. Twist and remove the socket from the lamp assembly
and pull the bulb out to remove.3. Push the bulb into the socket, twist the socket into the
lamp assembly and reinstall the lamp assembly into place
ensuring the locking tab is secure.
FLUID CAPACITIES
U.S.
Metric
Fuel (Approximate) 20 Gallons76 Liters
Engine Oil with Filter
3.3L and 3.8L Engine (SAE 5W-20, API Certified) 5 Quarts4.7 Liters
4.0L Engine (SAE 10W-30, API Certified) 5.5 Quarts5.2 Liters
Cooling System *
3.3L, 3.8L, and 4.0L Engine (MOPAR Engine Coolant/
Antifreeze 5 Year/100,000 Mile Formula or equivalent) 13.4 Quarts
12.6 Liters
* Includes heater and coolant recovery bottle filled to MAX level. Add 2.9 Qts (2.8 L) if equipped with a rear
heater.
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FLUIDS, LUBRICANTS AND GENUINE PARTS
Engine
ComponentFluid, Lubricant, or Genuine Part
Engine Coolant MOPAR
Antifreeze/Coolant Five Year/100,000 Mile Formula HOAT
(Hybrid Organic Additive Technology) or equivalent.
Engine Oil – 3.3L and 3.8L Engines Use API Certified SAE 5W-20 Engine Oil, meeting the requirements of
Chrysler Material Standard MS-6395. Refer to your oil filler cap for cor-
rect SAE grade.
Engine Oil – 4.0L Engine Use API Certified SAE 10W-30 Engine Oil, meeting the requirements of
Chrysler Material Standard MS-6395. Refer to your oil filler cap for cor-
rect SAE grade.
Engine Oil Filter MOPAREngine Oil Filter or equivalent.
Spark Plugs – 3.3L and 3.8L Engines RE14PLP5 (Gap 0.050 in [1.27 mm])
Spark Plugs – 4.0L Engine ZFR5LP-13G (Gap 0.050 in [1.27 mm])
Fuel Selection – 3.3L and 3.8L En-
gines 87 Octane
Fuel Selection – 4.0L Engine 87 Octane Acceptable — 89 Recommended
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