service DODGE CARAVAN 2010 Service Manual

Curb Weight
The curb weight of a vehicle is defined as the total weight
of the vehicle with all fluids, including vehicle fuel, at full
capacity conditions, and with no occupants or cargo
loaded into the vehicle. The front and rear curb weight
values are determined by weighing your vehicle on a
commercial scale before any occupants or cargo are
added.
Overloading
The load carrying components (axle, springs, tires,
wheels, etc.) of your vehicle will provide satisfactory
service as long as you do not exceed the GVWR and front
and rear GAWR.
The best way to figure out the total weight of your
vehicle is to weigh it when it is fully loaded and ready for
operation. Weigh it on a commercial scale to ensure that
it is not over the GVWR.Figure out the weight on the front and rear of the vehicle
separately. It is important that you distribute the load
evenly over the front and rear axles.
Overloading can cause potential safety hazards and
shorten useful service life. Heavier axles or suspension
components do not necessarily increase the vehicle’s
GVWR.
Loading
To load your vehicle properly, first figure out its empty
weight, axle-by-axle and side-by-side. Store heavier items
down low and be sure you distribute their weight as
evenly as possible. Stow all loose items securely before
driving. If weighing the loaded vehicle shows that you
have exceeded either GAWR, but the total load is within
the specified GVWR, you must redistribute the weight.
Improper weight distribution can have an adverse effect
on the way your vehicle steers and handles, and the way
the brakes operate.5
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•You can also turn the temperature control to maximum
heat, the mode control to floor and the blower control
to high. This allows the heater core to act as a
supplement to the radiator and aids in removing heat
from the engine cooling system.
CAUTION!
Driving with a hot cooling system could damage
your vehicle. If temperature gauge reads “H”, pull
over and stop the vehicle. Idle the vehicle with the air
conditioner turned off until the pointer drops back
into the normal range. If the pointer remains on the
“H”, turn the engine off immediately, and call for
service.
WARNING!
You or others can be badly burned by hot engine
coolant (antifreeze) or steam from your radiator. If
you see or hear steam coming from under the hood,
do not open the hood until the radiator has had time
to cool. Never try to open a cooling system pressure
cap when the radiator or coolant bottle is hot.
JACKING AND TIRE CHANGING
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.(Continued)
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WARNING! (Continued)
•The jack is designed to use as a tool for changing
tires only. The jack should not be used to lift the
vehicle for service purposes. The vehicle should
be jacked on a firm level surface only. Avoid ice or
slippery areas.
•If it is necessary to retrieve the spare tire from
under the vehicle on the side of the vehicle close to
moving traffic. Pull far enough off the road to
avoid the danger of being hit.
Jack Location
The jack, jack handle and winch handle tools are stowed
behind the rear left side trim panel in the rear cargo area.
Turn the two cover latches to release the cover.Remove the pouch containing the scissors jack, jack
handle, and tools.
Jack And Tool Location
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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.
NOTE: If either front tire is flat, it may be necessary to
jack up the vehicle to remove the compact spare tire/
cover assembly from under the vehicle. Refer to jack
engagement locations in the following steps for proper
jack placement. 4. When the compact spare tire/cover assembly is clear
of the vehicle, stand the tire/cover assembly upright and
remove the wheel spacer by squeezing the two retainer
tabs together.
Spare Tire Hook And Removal
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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. The
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 “T” and fit the winch “T” 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 the tire pressure, as required.
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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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“Electronic Vehicle Information Center (EVIC)” in ”Un-
derstanding Your Instrument Panel” for further informa-
tion. Tighten the gas cap until aclickingsound is heard.
This is an indication that the gas cap is properly tight-
ened.
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. This might indicate a damaged
cap. If the problem is detected twice in a row, the system
will turn on the MIL. Resolving the problem will turn the
MIL light off.
EMISSIONS INSPECTION AND MAINTENANCE
PROGRAMS
In some localities, it may be a legal requirement to pass
an inspection of your 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 may notbe ready if your 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, your vehicle may fail the test.
Your vehicle has a simple ignition key-actuated test,
which you can use prior to going to the test station. To
check if your vehicle’s OBD II system is ready, you must
do the following:
1. Turn the ignition switch to the ON position, but do not
crank or start the engine.
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2. If you crank or start the engine, you will have to start
this test over.
3. As soon as you turn the ignition switch to the ON
position, you will see the MIL symbol come on as part of
a normal bulb check.
4. 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 OFF
the ignition or start the engine. This means that your
vehicle’s OBD II system is not readyand you should
not proceed to the I/M station.
b. The MIL will not flash at all and will remain fully
illuminated until you turn OFF the ignition or start the
engine. This means that your vehicle’s OBD II system
is ready and you can proceed to the I/M station. If your OBD II system is
not ready,you should see your
authorized dealer or repair facility. If your vehicle was
recently serviced or had a battery failure or replacement,
you may need to do nothing more than drive your
vehicle as you normally would in order for your OBD II
system to update. A recheck with the above test routine
may then indicate that the system is now ready.
Regardless of whether your vehicle’s OBD II system is
ready or not, if the MIL is illuminated during normal
vehicle operation you should have your vehicle serviced
before going to the I/M station. The I/M station can fail
your vehicle because the MIL is on with the engine
running.
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REPLACEMENT PARTS
Use of genuine MOPARparts for normal/scheduled
maintenance and repairs is highly recommended to en-
sure the designed performance. Damage or failures
caused by the use of non-MOPAR parts for maintenance
and repairs will not be covered by the manufacturer’s
warranty.
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 may void your warranty and could 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 me-
chanic.
MAINTENANCE PROCEDURES
The pages that follow contain the requiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides those maintenance items specified in the fixed
maintenance schedule, there are other components which
may require servicing or replacement in the future.
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