maintenance DODGE POWER WAGON 2005 2.G User Guide

Carbon Monoxide Warnings
WARNING!
Carbon monoxide (CO) in exhaust gases is deadly.
Follow the precautions below to prevent carbon
monoxide poisoning:
•Do not inhale exhaust gases. They contain carbon
monoxide, a colorless and odorless gas which can kill.
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 mainte-
nance. Have the exhaust system inspected every timethe vehicle is raised. Have any abnormal 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 ex-
haust gases from entering the vehicle.
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 converter will not
require maintenance. However, you must keep the en-
gine maintained to assure proper operation and prevent
possible damage.
NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
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5

CAUTION!
•During the first 500 miles (805 km) your new
vehicle is driven, do not tow a trailer. Doing so
may damage your vehicle.
•When first towing a trailer, limit your speed to 50
mph (80 km/h) during the first 500 miles (805 km)
of towing.
Consider the following items when computing the
weight on the rear axle:
•the tongue weight of the trailer
•the weight of any other type of cargo or equipment put
in or on your vehicleNOTE:Remember that everything put into or on the
trailer adds to the load on your vehicle. Also, additional
factory-installed options, or dealer-installed options,
must be considered as part of the total load on your
vehicle. Refer to the Certification label located at the
driver’s door for the Gross Vehicle Weight Rating.
WARNING!
Improper towing can lead to an injury accident.
Follow these guidelines to make your trailer towing
as safe as possible:
Perform the maintenance listed in the“Maintenance
Schedules”section of this manual (Section 8). When
towing a trailer, never exceed the Gross Axle Weight
Rating (GAWR), or Gross Combined Vehicle Weight
(GCVW).
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5

•Air Conditioning—turn it off temporarily.
•Hilly Terrain—Turn overdrive off.
See Cooling System Operating information in the Service
and Maintenance section of this manual for more infor-
mation.
Automatic Transmission Oil Temperature Warning
Light
All vehicles with automatic transmissions are equipped
with a transmission sump oil temperature sensor and
warning light. If elevated transmission temperatures are
encountered, the engine controller will select the most
desirable gear until the transmission temperatures are
reduced. If transmission oil temperatures continue to
rise, a warning light located in the instrument cluster will
illuminate. If this should occur, stop the vehicle, shift to
Neutral, and run the engine at idle or faster until the light
goes off.
Towing With An Automatic Transmission
Vehicles equipped with an automatic transmission may
shift into and out of Overdrive, or a lower gear, when
driving in hilly areas, when heavily loaded, or when
towing into heavy winds.
When this condition occurs, select TOW/HAUL mode or
shift into a lower gear to prevent excessive transmission
wear and/or overheating, and to provide better engine
braking.
NOTE:Do not exceed the following RPM while manu-
ally downshifting:
•5600 rpm with 5.7L engines.
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MAINTAINING YOUR VEHICLE
CONTENTS

Engine Compartment—5.7L...............352

Onboard Diagnostic System (OBD II).........353

Emissions Inspection And Maintenance
Programs............................353

Dealer Service.........................355

Replacement Parts......................356

Maintenance Procedures..................356
▫Engine Oil..........................356
▫Engine Oil Filter......................360▫Drive Belts—Check Condition And
Tensioner...........................360
▫Spark Plugs.........................361
▫Engine Air Cleaner Filter................361
▫Engine Fuel Filter.....................362
▫Catalytic Converter....................362
▫Emission-Related Components............364
▫Maintenance Free Battery................364
▫Air Conditioner Maintenance.............365
7

▫Power Steering—Fluid Check............367
▫Front Suspension Ball Joints..............367
▫Steering Linkage—Inspection............368
▫Front Prop Shaft Lubrication.............368
▫Body Lubrication.....................369
▫Windshield Wiper Blades................369
▫Windshield Washers...................369
▫Exhaust System......................370
▫Cooling System.......................371
▫Hoses And Vacuum/Vapor Harnesses.......375
▫Brake System........................376
▫Clutch Hydraulic System................377
▫Clutch Linkage.......................378▫Rear Axle And 4X4 Front Driving Axle Fluid
Level..............................378
▫Transfer Case........................379
▫Front Drive Shaft.....................379
▫Manual Transmission..................379
▫Automatic Transmission................380
▫Front Wheel Bearings..................383
▫Selection Of Lubricating Grease...........383
▫Noise Control System Required Maintenance
& Warranty.........................384
▫Appearance Care And Protection From
Corrosion...........................388

Fuse And Relay Center...................393

Vehicle Storage........................393
350 MAINTAINING YOUR VEHICLE

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 driveable and not
need towing, see your dealer for service as soon as
possible.CAUTION!
Prolonged driving with the“Malfunction Indicator
Light”on could cause further damage to the emis-
sion control system. It could also affect fuel economy
and driveability. The vehicle must be serviced before
any emissions tests can be performed.
If the“Malfunction Indicator Light”is flashing,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.
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.
MAINTAINING YOUR VEHICLE 353
7

For states which have an I/M (Inspection and
Maintenance) requirement, this check verifies the
following: the MIL (Malfunction Indicator Lamp)
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 maynotbe 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.
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 light will blink for approximately 5 sec-
onds and then remain on until the first engine crank or
the key is turned off. This means that your vehicle’s
OBD system isnot readyand you shouldnotproceed
to the I/M station.
354 MAINTAINING YOUR VEHICLE

WARNING!
You can be badly injured working on or around a
motor vehicle. Do only that 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.
REPLACEMENT PARTS
Use of genuine Moparparts 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.
MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
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.
Engine Oil
Checking Oil Level
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. The
best time to check the engine oil level is about 5 minutes
after a fully warmed up engine is shut off or before
starting the engine after it has sat overnight.
356 MAINTAINING YOUR VEHICLE

•More than 50% of your driving is at sustained high
speeds during hot weather, above 32°C (90°F)
•Trailer towing
•Heavy Loading
•Taxi, Police or delivery service (commercial service)
•Off-road or desert operation
•If equipped for and operating with E-85 (ethanol)
fuel.
NOTE:IfANYof these apply to you then change your
engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule“B”of the
Maintenance Schedulessection of this manual.
If none of these apply to you, then change your engine oil
at every interval shown on scheduleAof theMainte-
nance Schedulessection of this manual.
Dusty Conditions
Driving through dust-laden air increases the problems of
keeping abrasive materials out of the engine. Under these
conditions, special attention should be given to the
engine air cleaner, the crankcase inlet air cleaner and the
crankcase ventilation system. Make sure that these units
are clean at all times. This will tend to reduce to a
minimum the amount of abrasive material that may enter
the engine.
Engine Oil Selection
For best performance and maximum protection under all
types of operating conditions, the manufacture only
recommends engine oils that are API certified and meet
the requirements of DaimlerChrysler Material Standard
MS-6395. Use Mopar or an equivalent oil meeting the
specification MS-6395.
358 MAINTAINING YOUR VEHICLE

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
The manufacturer’s 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 Tensioner
Belt tension is controlled by means of an automatic
tensioner. No belt tension adjustments are required.
However, belt and belt tensioner condition should be
inspected at the specified intervals and replaced if re-
quired. See your authorized dealer for service.
At the mileage indicated in the maintenance schedule, all
belts and tensioner should be checked for condition.
Improper belt tension can cause belt slippage and failure.
360 MAINTAINING YOUR VEHICLE