engine DODGE GRAND CARAVAN 2007 Repair Manual

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.” 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 dealer for service as soon as
possible. CAUTION!• Prolonged driving with the “Malfunction Indica-
tor Light” 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.
• If the “Malfunction Indicator Light” is flashing
while the engine is running, severe catalytic con-
verter damage and power loss will soon occur.
Immediate service is required.
Loose Fuel Filler Cap Message
After fuel is added, the vehicle diagnostic system can
determine if the fuel filler cap is loose, improperly
installed, or damaged. A loose fuel filler cap message will
be displayed in the instrument cluster. Tighten the gas416 MAINTAINING YOUR VEHICLE

cap until a  clicking  sound 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. This might indicate a damaged cap. If
the problem is detected twice in a row, the system will
turn on the Malfunction Indicator Light (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, which have an I/M (Inspection and
Maintenance) requirement, this check verifies the
following: the MIL (Malfunction Indicator Light) is functioning and is not on when the engine is running,
and that the OBD (On Board Diagnostic) system is ready
for testing.
Normally, the OBD system will be ready. The OBD
system may not be ready if your vehicle was recently
serviced, if you recently had a dead battery, or a battery
replacement. If the OBD 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 system is ready, you must do
the following:
1. Insert your 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. MAINTAINING YOUR VEHICLE 417
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4. As soon as you turn your key to the ON position, you
will see your 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 off the
ignition key or start the engine. This means that your
vehicle’s OBD system is not ready and 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 key or start
the engine. This means that your vehicle’s OBD system
is ready and you can proceed to the I/M station.
If your OBD 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
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 system is
ready or not ready, if the MIL symbol 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 symbol is on
with the engine running.
REPLACEMENT PARTS
Use of genuine Mopar  parts for normal/scheduled
maintenance and repairs is highly recommended to in-
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.418 MAINTAINING YOUR VEHICLE

DEALER SERVICE
Your dealer has the qualified service personnel, 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 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. MAINTENANCE PROCEDURES
The pages that follow contain the required maintenance
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. MAINTAINING YOUR VEHICLE 419
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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 5
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.
CAUTION!Overfilling or underfilling will cause oil aeration or
loss of oil pressure. This could damage your engine. Engine Oil Dipstick420 MAINTAINING YOUR VEHICLE

Change Engine Oil
Road conditions and your kind of driving affects the
interval at which your oil should be changed. Check the
following list to see if any apply to you.
• Day or night temperatures are below 32°F (0°C).
• Stop and Go driving.
• Extensive engine idling.
• Driving in dusty conditions.
• Short trips of less than 10 miles (16 km).
• More than 50% of your driving is at sustained high
speeds during hot weather, above 90°F (32°C).
• Trailer towing.
• Taxi, Police or delivery service (commercial service).
• Off-Road or desert operation. • If equipped for and operating with E-85 (ethanol)
fuel.
If ANY of these apply to you, then change your engine oil
at every interval shown in schedule “B” of the “Mainte-
nance Schedules” section of this manual.
If none of these apply to you, then change your engine oil
at every interval shown on schedule “A” of the “Main-
tenance Schedules” section of this manual
NOTE: Under no circumstances should oil change in-
tervals exceed 6000 miles (10 000 km) or 6 months
whichever comes first.
Engine Oil Selection
For best performance and maximum protection under all
types of operating conditions, the manufacturer only
recommends engine oils that are API certified and meet
the requirements of DaimlerChrysler Material Standard
MS-6395. MAINTAINING YOUR VEHICLE 421
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American Petroleum Institute (API) Engine Oil
Identification Symbol
This symbol means that the oil has
been certified by the American
Petroleum Institute (API). The
manufacturer only recommends
API Certified engine oils.
Engine Oil Viscosity (SAE Grade) — 2.4 Liter
Engines
SAE 5W-30 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
the Engine Compartment illustration in this section.
Lubricants which do not have both, the engine oil certi-
fication mark and the correct SAE viscosity grade num-
ber should not be used.
Engine Oil Viscosity (SAE Grade) — 3.3/3.8 Liter
Engines
SAE 5W-20 engine oil is recommended for all operating
temperatures. This engine oil improves low temperature
starting and vehicle fuel economy. Refer to your engine
oil filler cap for the recommended engine oil viscosity for
your vehicle.
For information on engine oil filler cap location, refer to
the Engine Compartment illustration in this section.
Lubricants which do not have both, the engine oil certi-
fication mark and the correct SAE viscosity grade num-
ber should not be used.422 MAINTAINING YOUR VEHICLE

Synthetic Engine Oils
There are a number of engine oils being promoted as
either synthetic or semi-synthetic. If you chose to use
such a product, use only those oils that are American
Petroleum Institute (API) Certified and have the recom-
mended SAE viscosity grade. Follow the maintenance
schedule that describes your driving type.
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
it’s performance may be impaired by supplemental ad-
ditives.
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 dealer, service station, 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
All the manufacturers 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. Mopar Engine Oil Filters are a high quality oil
filter and are recommended.
Drive Belts — Check Condition and Tension
At the mileage indicated in the maintenance schedule, all
belts should be checked for condition and proper tension.
Improper belt tension can cause belt slippage and failure. MAINTAINING YOUR VEHICLE 423
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Belts should be inspected for evidence of cuts, cracks, or
glazing, and replaced if there is indication of damage
which could result in belt failure. If adjustment is re-
quired, the belts must be adjusted according to the
specifications and procedures described in the Service
Manual. Low generator belt tension can cause battery
failure. A special tool is required to properly measure
tension and to restore belt tension to factory specifica-
tions.
Also check belt routing to make sure there is no interfer-
ence between the belts and other engine components.
Spark Plugs
Spark plugs must fire properly to assure engine perfor-
mance and emission control. New plugs should be in-
stalled at the specified mileage. The entire set should be replaced if there is any malfunction due to a faulty spark
plug, malfunctioning spark plugs can damage the cata-
lytic converter. For proper type of replacement spark
plugs, refer to the “Vehicle Emission Control Informa-
tion” label in the engine compartment.
Engine Air Cleaner Filter
Under normal driving conditions, replace the air filter at
the intervals shown on Schedule “A”. If, however, you
drive the vehicle frequently under dusty or severe con-
ditions, the filter element should be inspected periodi-
cally and replaced if necessary at the intervals shown on
Schedule “B”.424 MAINTAINING YOUR VEHICLE

WARNING!The air cleaner can provide a measure of protection
in the case of engine backfire. Do not remove the air
cleaner unless such removal is necessary for repair or
maintenance. Make sure that no one is near the
engine compartment before starting the vehicle with
the air cleaner removed. Failure to do so can result in
serious personal injury.
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. MAINTAINING YOUR VEHICLE 425
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