2009 DODGE CARAVAN Owners Manual

MAINTAINING YOUR VEHICLE
CONTENTS
Engine Compartment — 3.3/3.8L.......... 433
Engine Compartment — 4.0L............. 434
Onboard Diagnostic System — OBD II....... 435
▫Loose Fuel Filler Cap Message — Gascap . . . 435
Emissions Inspection And Maintenance
Programs............................ 436
Replacement Parts..................... 437
Dealer Service........................ 438
Maintenance Procedures................. 438▫Engine Oil......................... 438
▫Engine Oil Filter..................... 441
▫Engine Air Cleaner Filter............... 441
▫Exhaust System...................... 442
▫Maintenance-Free Battery............... 444
▫Air Conditioner Maintenance............ 446
▫Steering Shaft Seal.................... 448
▫Drive Shaft Universal Joints............. 448
▫Body Lubrication..................... 448
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▫Windshield Wiper Blades............... 449
▫Cooling System...................... 450
▫Brakes............................ 456
▫Automatic Transaxle.................. 458
▫Appearance Care And Protection From
Corrosion.......................... 460
▫Cleaning The Instrument Panel Cupholders . . 466
Fuses.............................. 467
▫Totally Integrated Power Module (TIPM).... 467
Vehicle Storage....................... 474
Replacement Light Bulbs................. 474
Bulb Replacement..................... 475▫Headlights......................... 475
▫Front Park/Turn Signal Lights........... 476
▫Fog Lights......................... 476
▫Rear Tail, Stop, Turn Signal, Side Marker
And Backup Lights................... 477
▫Center High-Mounted Stop Light (CHMSL) . . 478
▫License Light....................... 478
Fluids And Capacities................... 479
Fluids, Lubricants And Genuine Parts....... 480
▫Engine............................ 480
▫Chassis............................ 481
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ENGINE COMPARTMENT — 3.3/3.8L
1 — Air Cleaner Filter 7 — Engine Oil Fill
2 — Automatic Transmission Dipstick (3.3L Only) 8 — Engine Oil Dipstick
3 — Brake Fluid Reservoir 9 — Coolant Pressure Cap
4 — Battery 10 — Washer Fluid Reservoir
5 — Totally Integrated Power Module 11 — Power Steering Fluid Reservoir
6 — Engine Coolant ReservoirMAINTAINING YOUR VEHICLE 433
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ENGINE COMPARTMENT — 4.0L
1 — Power Steering Fluid Reservoir 7 — Engine Oil Dipstick
2 — Air Cleaner Filter 8 — Engine Oil Fill
3 — Brake Fluid Reservoir 9 — Coolant Pressure Cap
4 — Battery 10 — Washer Fluid Reservoir
5 — Totally Integrated Power Module
6 — Engine Coolant Reservoir 434 MAINTAINING YOUR VEHICLE
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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.” 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 “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 — gASCAP
Should the “Loose Fuel Filler Cap” or “gASCAP” mes-
sage appear, there may be a problem in the evaporative
system. Before taking the vehicle into an authorized
dealer, check first to see if the fuel filler cap is possibly
loose, improperly installed, or damaged. A loose fuel
MAINTAINING YOUR VEHICLE 435
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filler cap message will be displayed in the instrument
cluster. Tighten the gas cap until aclickingsound 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. If the problem
is detected twice in a row, the system will turn on the
Malfunction Indicator Light (MIL). Resolving the prob-
lem will turn the MIL light off. Take your vehicle in to an
authorized dealer.
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 MalfunctionIndicator 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 maynotbe 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. 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.
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4. As soon as you turn your key to the ON position, you
will see the 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 or start the engine. This means that your
vehicle’s OBD II system isnot readyand you should
notproceed 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
isready, and you can proceed to the I/M station.
If your OBD II system isnot 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 ready, 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.
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-MOPARparts for maintenance
and repairs will not be covered by the manufacturer’s
warranty.
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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 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 me-
chanic.
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 engine lubrication, the engine oil must
be maintained at the correct level. Check the oil level at
regular intervals, such as every fuel stop.
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