Dodge Caravan 2002 2007 Factory Service Manual

Full download: http://manualplace.com/download/dodge-caravan-2002-2007-factory-service-manual/

GROUP TAB LOCATOR

Introduction

0 Lubrication & Maintenance

2 Suspension

3 Differential & Driveline

5 Brakes

7 Cooling

8A Audio

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8M Message Systems

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8T Navigation/Telecommunication

8W Wiring

9 Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission/Transaxle

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)

This is the cut pages sample. Download all 2338 page(s) at: ManualPlace.com
RS INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

BODY CODE PLATE TORQUE REFERENCES

DESCRIPTION . . . . . . . . . . ................1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FASTENER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . ................2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FASTENER USAGE VEHICLE CERTIFICATION LABEL
DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
FASTENER USAGE . . . . . ................5 E-MARK LABEL
THREADED HOLE REPAIR ...............5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTERNATIONAL SYMBOLS VECI LABEL
DESCRIPTION . . . . . . . . . . ................5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
METRIC SYSTEM MANUFACTURER PLATE
DESCRIPTION . . . . . . . . . . ................6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11

BODY CODE PLATE

DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.

BODY CODE PLATE – LINE 3

DIGITS 1 THROUGH 12
Vehicle Order Number

DIGITS 13 THROUGH 17
Open Space Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
DIGITS 18 AND 19 2 - SECONDARY PAINT
3 - VINYL ROOF
Vehicle Shell Line 4 - VEHICLE ORDER NUMBER
• RS 5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
DIGIT 20 8 - TRIM
Carline 9 - TRANSMISSION
10 - MARKET
11 - VIN
FWD
• K = Dodge AWD
• Y = Chrysler • C = Chrysler
• D = Dodge
2 INTRODUCTION RS
BODY CODE PLATE (Continued)
DIGIT 21 BODY CODE PLATE LINE 1
Price Class
• H = Highline DIGITS 1, 2, AND 3
• L = Lowline Transaxle Codes
• P = Premium • DGC = 31TH 3-Speed Automatic Transaxle
• S = Luxury • DGL = 41AE/TE 4-Speed Electronic Automatic
• X = Premium • DDR = T850 5-Speed Manual Transaxle

DIGITS 22 AND 23 DIGIT 4

Body Type Open Space
• 52 = Short Wheel Base
• 53 = Long Wheel Base DIGIT 5
Market Code
BODY CODE PLATE LINE 2 • C = Canada
• B = International
DIGITS 1, 2 AND 3 • M = Mexico
Paint Procedure • U = United States

DIGIT 4 DIGIT 6
Open Space Open Space

DIGITS 5 THROUGH 7 DIGITS 7 THROUGH 23

Primary Paint (Refer to 23 - BODY/PAINT - SPEC- Vehicle Identification Number
IFICATIONS). • Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
DIGIT 8 AND 9
Open Space IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
DIGITS 10 THROUGH 12 lowed by END. When two plates are required, the
Secondary Paint last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
DIGIT 13 AND 14 spaces of each line will not be used due to overlap of
Open Space the plates.

DIGITS 15 THROUGH 18
Interior Trim Code FASTENER IDENTIFICATION
DIGIT 19 DESCRIPTION
Open Space The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
DIGITS 20, 21, AND 22 the bolt strength. Identification is determined by the
Engine Code line marks on the top of each bolt head. The actual
• EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline bolt strength grade corresponds to the number of line
(MPI) marks plus 2. The most commonly used metric bolt
• EGA = 3.3L 6 cyl. Gasoline (SMPI) strength classes are 9.8 and 10.9. The metric
• EGH = 3.8L 6 cyl. Gasoline (SMPI) strength class identification number is imprinted on
• EGM = 3.3L 6 cyl. Ethanol Flexible Fuel the head of the bolt. The higher the class number,
• ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
DIGIT 23 nut face. Refer to the Fastener Identification and
Open Space Fastener Strength Charts.
RS INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

FASTENER IDENTIFICATION
4 INTRODUCTION RS
FASTENER IDENTIFICATION (Continued)

FASTENER STRENGTH
RS INTRODUCTION 5

FASTENER USAGE THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoilt recommen-
DESCRIPTION dations for application and repair procedures.

FASTENER USAGE
INTERNATIONAL SYMBOLS
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER- DESCRIPTION
SONAL INJURY. The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
Fasteners and torque specifications references in used to identify various instrument controls. The
this Service Manual are identified in metric and SAE symbols correspond to the controls and displays that
format. are located on the instrument panel.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Wind screen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
6 INTRODUCTION RS

METRIC SYSTEM The following chart will assist in converting metric

units to equivalent English and SAE units, or vise
versa.
DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x = Newton Meters N·m x 8.851 = in-lbs
0.11298 (N·m)
ft-lbs x = Newton Meters N·m x = ft-lbs
1.3558 (N·m) 0.7376
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x = Inches Hg
0.2961
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x = Inches
0.03937
Feet x = Meters (M) M x 3.281 = Feet
0.3048
Yards x = Meters M x = Yards
0.9144 1.0936
mph x = Kilometers/Hr. Km/h x = mph
1.6093 (Km/h) 0.6214
Feet/Sec x = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
0.3048
mph x = Meters/Sec (M/S) M/S x 2.237 = mph
0.4470
Kilometers/Hr. (Km/h) x = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
0.27778 (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert

torque values listed in metric Newton- meters (N·m).
Also, use the chart to convert between millimeters
(mm) and inches (in.).
RS INTRODUCTION 7
METRIC SYSTEM (Continued)

METRIC CONVERSION CHART

8 INTRODUCTION RS

TORQUE REFERENCES
DESCRIPTION

TORQUE SPECIFICATIONS
RS INTRODUCTION 9
TORQUE REFERENCES (Continued)
Individual Torque Charts appear within many or tion. The formula to use the check digit is not
the Groups. Refer to the Standard Torque Specifica- released to the general public.
tions Chart for torque references not listed in the
individual torque charts.

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel, near the left windshield
pillar (Fig. 2). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a Fig. 2 VEHICLE IDENTIFICATION NUMBER (VIN)
Check Digit at the ninth position of the vehicle iden- 1 - DEFROSTER OUTLET
2 - VEHICLE IDENTIFICATION NUMBER
tification number. The check digit is used by the 3 - HEATED WINDSHIELD GRID
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-

VIN CODE BREAKDOWN CHART

POSITION INTERPRETATION CODE = DESCRIPTION

Country of Origin 1 = Manufactured By DaimlerChrysler Corporation

1
2 = Manufactured By DaimlerChrysler Canada Inc.

2 Make D = Dodge

C = Chrysler

Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags

3
8 = Multipurpose Pass. Vehicle With Side Air Bags

4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.)

1 = Chrysler Caravan - FWD

P = Chrysler, Town & Country - FWD
P = Dodge, Caravan/Grand Caravan - FWD
P = Dodge, Caravan C/V, Grand Caravan C/V - FWD
T = Chrysler, Town & Country - AWD
5 Car Line T = Dodge, Grand Caravan - AWD
J = Chrysler, Voyager/Grand Voyager - FWD
Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Left Hand Drive
RS INTRODUCTION 11

VEHICLE CERTIFICATION
LABEL
DESCRIPTION
A vehicle certification label is attached to the rear
shutface of the driver’s door (Fig. 3). This label indi-
cates date of manufacture (month and year), Gross
Vehicle Weight Rating (GVWR), Gross Axle Weight
Rating (GAWR) front, Gross Axle Weight Rating
(GAWR) rear and the Vehicle Identification Number
(VIN). The Month, Day and Hour of manufacture is
also included.
All communications or inquiries regarding the
vehicle should include the Month-Day-Hour and
Vehicle Identification Number. Fig. 4 E-MARK LABEL
1 - COUNTRY CODE
2 - REGULATION NUMBER
3 - APPROVAL NUMBER
4 - AMENDMENT NUMBER

VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
The label contains the vehicle’s emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
Fig. 3 VEHICLE CERTIFICATION LABEL - TYPICAL
E-MARK LABEL MANUFACTURER PLATE

DESCRIPTION DESCRIPTION
The Manufacturer Plate (Fig. 5) is located in the
An E-mark Label (Fig. 4) is located on the rear
engine compartment on the passenger side rear cor-
shut face of the driver’s door. The label contains the
ner of the hood. The plate contains five lines of infor-
following information:
mation:
• Date of Manufacture
1. Vehicle Identification Number (VIN)
• Month-Day-Hour (MDH)
2. Gross Vehicle Mass (GVM)
• Vehicle Identification Number (VIN)
3. Gross Train Mass (GTM)
• Country Codes
4. Gross Front Axle Rating (GFAR)
• Regulation Number
5. Gross Rear Axle Rating (GRAR)
• Regulation Amendment Number
• Approval Number

Fig. 5 MANUFACTURER PLATE

RS LUBRICATION & MAINTENANCE 0-1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS FLUID CAPACITIES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....1 SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 6
FLUID TYPES FLUID FILL/CHECK LOCATIONS
DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - ENGINE OIL AND LUBRICATION POINTS
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . ....1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - ENGINE COOLANT . . . . ....3 MAINTENANCE SCHEDULES
DESCRIPTION - FLEXIBLE FUEL ENGINE DESCRIPTION
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....3 DESCRIPTION ........................7
DESCRIPTION - AUTOMATIC/MANUAL DESCRIPTION - EXPORT . . . . . . . . . . . . . . . 13
TRANSAXLE FLUID . . . . . . . . . . . . . . . . . ....4 DESCRIPTION - DIESEL ENGINES -
DESCRIPTION - FUEL REQUIREMENTS . ....4 EXPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DESCRIPTION - FUEL REQUIREMENTS - HOISTING
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . ....6 STANDARD PROCEDURE - HOISTING . . . . . . . 24
DESCRIPTION - ENGINE OIL - DIESEL JUMP STARTING
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . ....6 STANDARD PROCEDURE - JUMP STARTING . 25
DESCRIPTION - AWD REAR DRIVELINE TOWING
MODULE FLUIDS . . . . . . . . . . . . . . . . . . ....6 STANDARD PROCEDURE - TOWING . . . . . . . . 26
DESCRIPTION - AWD POWER TRANSFER
UNIT FLUID . . . . . . . . . . . . . . . . . . . . . . . ....6

INTERNATIONAL SYMBOLS FLUID TYPES

DESCRIPTION
DaimlerChrysler Corporation uses international DESCRIPTION
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1). DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Fig. 1 INTERNATIONAL SYMBOLS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
0-2 LUBRICATION & MAINTENANCE RS
FLUID TYPES (Continued)
• Society of Automotive Engineers (SAE) that do not display the “Mark” on the front of the
• American Petroleum Institute (API) container should not be used (Fig. 2).
• National Lubricating Grease Institute (NLGI) DiamlerChrysler only recommends API Certified
engine oils that meet the requirements of Material
API CERTIFICATION AND LICENSE SYMBOL Standard MS-6395. Use Mopar or an equivalent oil
Use an engine oil that is API Certified (GF-3) and meeting the specification MS-6395.
Licensed to display the certification mark (Fig. 2).
MOPARt provides engine oils that meet or exceed, SYNTHETIC ENGINE OILS
Material Standard MS-6395 requirement. 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 cer-
tified by the American Petroleum Institute (API) to
display the “Certification Mark” and show SAE vis-
cosity grade recommended for each vehicle. Follow
the service schedule that describes your driving type.

ENGINE OIL ADDITIVES/SUPPLEMENTS

The manufacturer does not recommend the addi-
tion of any engine oil additives/supplements to the
Fig. 2 API Certification Mark specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil perfor-
SAE VISCOSITY mance. Engine oil additives/supplements should not
SAE 5W-20 and SAE 5W-30 engine oils are rec- be used to extend engine oil change intervals. No
ommended for all operating temperatures. additive is known to be safe for engine durability and
These engine oils are designed to improve low can degrade emission components. Additives can con-
temperature starting and vehicle fuel economy. tain undesirable materials that harm the long term
Refer to the engine oil filler cap for the pre- durability of engines by:
ferred engine oil viscosity grade for each vehi- • Increasing the level of Phosphorus and Sulfur in
cle (Fig. 3). SAE viscosity grades are used to specify the engine oil. The API Certified Engine Oils control
the correct viscosity oil for an engine. Use only Multi- the Phosphorus and Sulfur contents of the oil to lev-
Viscosity oils such as SAE 5W-20 or 5W-30. These els that reduce the contamination effect on the vehi-
are specified with a dual SAE viscosity grade which cles emission control system.
indicates the cold (5W) to hot (20, 30) temperature • Altering the viscosity characteristics of the
performance range of the oil. engine oil so that it no longer meets the require-
ments of the specified viscosity grade.
• Creating potential for an undesirable additive
compatibility interaction in the engine crankcase.
The engine oils contain a performance additive sys-
tem carefully developed to optimize the oils perfor-
mance in the engine. The addition of supplements
may cause the oil to thicken prematurely, cause
excessive deposit build up and potentially shorten
engine life.

AXLE LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the
Fig. 3 5W-30 Oil Filler Cap lubricants usage. Such as API GL-5 and SAE 75W-
90.
CONTAINER IDENTIFICATION
The Engine Oil Certificarion Mark was developed LUBRICANTS AND GREASES
and trademarked by the API to refer customers to Lubricating grease is rated for quality and usage
those engine oils preferred by the automobile manu- by the NLGI. All approved products have the NLGI
facturers. This symbol means that the oil has been symbol (Fig. 4) on the label. At the bottom of the
certified and licensed by the American Petroleum NLGI symbol is the usage and quality identification
Institute (API). This certification mark will only be letters. Wheel bearing lubricant is identified by the
found on the front of the oil containers. Those oils
RS LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)
letter “G”. Chassis lubricant is identified by the letter radiator where the tube/fin radiator can transfer the
“L”. The letter following the usage letter indicates heat to the air.
the quality of the lubricant. The following symbols The use of aluminum cylinder blocks, cylinder
indicate the highest quality. heads, and water pumps requires special corrosion
protection. Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37°C (-35°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
Fig. 4 NLGI SYMBOL tion.
1 - WHEEL BEARINGS The green coolant MUST NOT BE MIXED with
2 - CHASSIS LUBRICATION the orange or magenta coolants. When replacing cool-
3 - CHASSIS AND WHEEL BEARINGS ant the complete system flush must be performed
before using the replacement coolant.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may CAUTION: MoparT Antifreeze/Coolant, 5
require the use of specialized lubricants or oils. Con- Year/100,000 Mile Formula (MS-9769) may not be
sult the appropriate sections in this manual for the mixed with any other type of antifreeze. Doing so
correct application of these lubricants. will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
DESCRIPTION - ENGINE COOLANT coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL coolant as soon as possible.
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT- DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
ING. IF INHALED, MOVE TO FRESH AIR AREA. The information in this section is for Flexible Fuel
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT Vehicles (FFV) only. These vehicles can be identified
STORE IN OPEN OR UNMARKED CONTAINERS. by the unique Fuel Filler Door Label that states
WASH SKIN AND CLOTHING THOROUGHLY AFTER Ethanol (E-85) or Unleaded Gasoline Only. This sec-
COMING IN CONTACT WITH ETHYLENE GLYCOL. tion only covers those subjects that are unique to
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF these vehicles. Please refer to the other sections of
GLYCOL BASE COOLANT PROPERLY, CONTACT this manual for information on features that are
YOUR DEALER OR GOVERNMENT AGENCY FOR common between Flexible Fuel and gasoline only
LOCATION OF COLLECTION CENTER IN YOUR powered vehicles.
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR ETHANOL FUEL (E-85)
HOT UNDER PRESSURE, PERSONAL INJURY CAN E-85 is a mixture of approximately 85% fuel etha-
RESULT. AVOID RADIATOR COOLING FAN WHEN nol and 15% unleaded gasoline.
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT. WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
CAUTION: Use of Propylene Glycol based coolants cle when removing the fuel filler tube cap (gas cap)
is not recommended, as they provide less freeze or filling the tank. Do not use E-85 as a cleaning
protection and less boiling protection. agent and never use it near an open flame.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in FUEL REQUIREMENTS
the cylinder head area near the exhaust valves and The vehicle will operate on both unleaded gasoline
engine block. Then coolant carries the heat to the with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
0-4 LUBRICATION & MAINTENANCE RS
FLUID TYPES (Continued)
For best results, a refueling pattern that alternates TRANSMISSION FLUID
between E-85 and unleaded gasoline should be Mopart ATF+4 (Automatic Transmission Fluid) is
avoided. When you do switch fuels, it is recom- required in the 4XTE automatic and T850 manual
mended that transaxles. Substitute fluids can induce transmission
• you do not switch when the fuel gauge indicates problems and/or failure.
less than 1/4 full Mopart ATF+4 (Automatic Transmission Fluid)
• you do not add less than 5 gallons when refuel- when new is red in color. The ATF is dyed red so it
ing can be identified from other fluids used in the vehicle
• you operate the vehicle immediately after refuel- such as engine oil or antifreeze. The red color is not
ing for a period of at least 5 minutes permanent and is not an indicator of fluid condition.
Observing these precautions will avoid possible As the vehicle is driven, the ATF will begin to look
hard starting and/or significant deterioration in darker in color and may eventually become brown.
driveability during warm up. This is normal. ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
FFV STARTING cannot be used to indicate the fluid condition
The characteristics of E-85 fuel make it unsuitable or the need for a fluid change.
for use when ambient temperatures fall below 0°F. In
the range of 0°F to 32°F, you may experience an FLUID ADDITIVES
increase in the time it takes for your engine to start, DaimlerChrysler strongly recommends against the
and a deterioration in driveability (sags and/or hesi- addition of any fluids to the transmission, other than
tations) until the engine is fully warmed up. those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
Engine Operating on E-85 Fuel to aid in detecting fluid leaks.
If vehicle operates on E-85 fuel either full or part- Various “special” additives and supplements exist
time, use only Mopart Flexible Fuel 5W-30 engine oil that claim to improve shift feel and/or quality. These
or an equivalent that meets DaimlerChrysler Stan- additives and others also claim to improve converter
dard MS-9214. Equivalent commercial Flexible Fuel clutch operation and inhibit overheating, oxidation,
engine oils may be labeled as Multi-Fuel, Variable varnish, and sludge. These claims have not been sup-
Fuel, Flexible Fuel, etc. These engine oils may be ported to the satisfaction of DaimlerChrysler and
satisfactory if they meet the DaimlerChrysler Stan- these additives must not be used. The use of trans-
dard. mission “sealers” should also be avoided, since they
SAE 5W-30 engine oil is preferred for use in Flex- may adversely affect the integrity of transmission
ible Fuel engines. seals.

CAUTION: If Flexible Fuel engine oil is not used DESCRIPTION - FUEL REQUIREMENTS
when using E-85 fuel, engine wear or damage may Your engine is designed to meet all emissions reg-
result. ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
CRUISING RANGE having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
Because E-85 fuel contains less energy per gallon
gasoline will provide no benefit over high quality reg-
than gasoline, you will experience an increase in fuel
ular gasoline, and in some circumstances may result
consumption. You can expect your MPG and your
in poorer performance.
driving range to decrease by about 30% compared to
Light spark knock at low engine speeds is not
gasoline operation.
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
DESCRIPTION - AUTOMATIC/MANUAL immediate service is required. Engine damage result-
TRANSAXLE FLUID ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
NOTE: Refer to the maintenance schedules for the Poor quality gasoline can cause problems such as
recommended maintenance (fluid/filter change) hard starting, stalling and hesitations. If you experi-
intervals for these transaxles. ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
NOTE: All transaxles have a common transmission Over 40 auto manufacturers world-wide have
and differential sump. Filling the transaxle accom- issued and endorsed consistent gasoline specifications
modates the differential as well. (the Worldwide Fuel Charter, WWFC) to define fuel
RS LUBRICATION & MAINTENANCE 0-5
FLUID TYPES (Continued)
properties necessary to deliver enhanced emissions, adversely affected. Gasoline sold outside of California
performance and durability for your vehicle. We rec- is permitted to have higher sulfur levels which may
ommend the use of gasolines that meet the WWFC affect the performance of the vehicle’s catalytic con-
specifications if they are available. verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
REFORMULATED GASOLINE light to illuminate. We recommend that you try a dif-
Many areas of the country require the use of ferent brand of unleaded gasoline having lower sulfur
cleaner burning gasoline referred to as “reformu- to determine if the problem is fuel related prior to
lated” gasoline. Reformulated gasoline contain oxy- returning your vehicle to an authorized dealer for
genates, and are specifically blended to reduce service.
vehicle emissions and improve air quality.
We strongly support the use of reformulated gaso- CAUTION: If the Malfunction Indicator Lamp (MIL),
line. Properly blended reformulated gasoline will pro- Check Engine or Service Engine Soon light is flash-
vide excellent performance and durability for the ing, immediate service is required; see on-board
engine and fuel system components. diagnostics system section.

GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with MATERIALS ADDED TO FUEL
oxygenates such as 10% ethanol, MTBE, and ETBE. All gasoline sold in the United States and Canada
Oxygenates are required in some areas of the country are required to contain effective detergent additives.
during the winter months to reduce carbon monoxide Use of additional detergents or other additives is not
emissions. Fuels blended with these oxygenates may needed under normal conditions.
be used in your vehicle.
FUEL SYSTEM CAUTIONS
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage CAUTION: Follow these guidelines to maintain your
critical fuel system components. vehicle’s performance:

• The use of leaded gas is prohibited by Federal

MMT IN GASOLINE law. Using leaded gasoline can impair engine perfor-
MMT is a manganese-containing metallic additive mance, damage the emission control system, and
that is blended into some gasoline to increase octane. could result in loss of warranty coverage.
Gasoline blended with MMT provide no performance • An out-of-tune engine, or certain fuel or ignition
advantage beyond gasoline of the same octane num- malfunctions, can cause the catalytic converter to
ber without MMT. Gasoline blended with MMT overheat. If you notice a pungent burning odor or
reduce spark plug life and reduce emission system some light smoke, your engine may be out of tune or
performance in some vehicles. We recommend that malfunctioning and may require immediate service.
gasoline free of MMT be used in your vehicle. The Contact your dealer for service assistance.
MMT content of gasoline may not be indicated on the • When pulling a heavy load or driving a fully
gasoline pump; therefore, you should ask your gaso- loaded vehicle when the humidity is low and the tem-
line retailer whether or not his/her gasoline contains perature is high, use a premium unleaded fuel to
MMT. help prevent spark knock. If spark knock persists,
It is even more important to look for gasoline with- lighten the load, or engine piston damage may result.
out MMT in Canada because MMT can be used at • The use of fuel additives which are now being
levels higher than allowed in the United States. sold as octane enhancers is not recommended. Most
MMT is prohibited in Federal and California refor- of these products contain high concentrations of
mulated gasoline. methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
SULFUR IN GASOLINE or additives is not the responsibility of
If you live in the northeast United States, your DaimlerChrysler Corporation and may not be covered
vehicle may have been designed to meet California under the new vehicle warranty.
low emission standards with Cleaner-Burning Cali-
NOTE: Intentional tampering with emissions control
fornia reformulated gasoline with low sulfur. If such
systems can result in civil penalties being assessed
fuels are not available in states adopting California
against you.
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may be
0-6 LUBRICATION & MAINTENANCE RS
FLUID TYPES (Continued)

DESCRIPTION - FUEL REQUIREMENTS - The recommended lubricant for the Overrunning

Clutch Housing is Mopart ATF+4. The recommended
DIESEL ENGINE
lubricant for the Differential Carrier is Mopart
WARNING: DO NOT USE ALCOHOL OR GASOLINE 80W-90 Gear and Axle Lubricant.
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND DESCRIPTION - AWD POWER TRANSFER UNIT
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH FLUID
DIESEL FUEL. The recommended lubricant for the AWD Power
Transfer Unit is Mopart Gear and Axle Lubricant
Use good quality diesel fuel from a reputable sup- 80W-90.
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class 0 - 4) will provide
good performance. If the vehicle is exposed to FLUID CAPACITIES
extreme cold (below -18°C/0°F) or is required to oper-
ate at colder than normal conditions for prolonged SPECIFICATIONS - FLUID CAPACITIES
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
DESCRIPTION SPECIFICATION
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN Fuel Tank (Gas) 75 L (20 gal.)
590. This will provide better protection from fuel gel- Fuel Tank (Diesel) 75 L (20 gal.)
ling or wax plugging of the fuel filters. Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez- Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
ing in winter, drain the accumulated water from the Engine Oil* - 2.5 L
6.0 L (6.3 qts.)
fuel/water separator using the fuel/water separator (Diesel)
drain provided. If you buy good quality fuel and follow Cooling System** - 2.4 L 10.7 L (11.4 qts.)
the cold weather advice above, fuel conditioners should
Cooling System** - 2.5 L
not be required in your vehicle. If available in your
Turbo Diesel with 13.8 L (14.6 qts.)
area, a high cetane “premium” diesel fuel may offer
Auxiliary Heater
improved cold starting and warm up performance.
Cooling System** -
DESCRIPTION - ENGINE OIL - DIESEL 3.3/3.8 L without Auxiliary 12.6 L (13.4 qts.)
Heater
ENGINES
Use only Diesel Engine Oil meeting standard MIL- Cooling System** -
2104C or API Classification CD or higher or CCML 3.3/3.8 L with Auxiliary 15.4 L (16.3 qts.)
D4, D5. Heater
Automatic Transaxle -
SAE VISCOSITY GRADE 3.8 L (4.0 qts.)
Service Fill
CAUTION: Low viscosity oils must have the proper Automatic Transaxle -
9.2 L (9.7 qts.)
API quality or the CCMC G5 designation. 4XTE Overhaul Fill
Manual Transaxle (T850
To assure of properly formulated engine oils, it is 2.4-2.7 L (2.5-2.9 qts.)
5-Speed)
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be AWD Power Transfer Unit 1.15 L (2.4 pts.)
used in accordance to ACEA B3, B4 specification. Power Steering 1.2 L (2.5 pts.)
European Grade 10W-40 oils are also acceptable. AWD Bi-directional
Oils of the SAE 5W-40 grade number are preferred 0.575 L (1.22 pts.)
Overrunning Clutch
when minimum temperatures consistently fall below
-15°C. AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
DESCRIPTION - AWD REAR DRIVELINE ** (includes heater and recovery/reserve bottle)
MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Hous-
ing (front) and the Differential Carrier (rear).
RS LUBRICATION & MAINTENANCE 0-7

FLUID FILL/CHECK At Each Stop for Fuel

• Check the engine oil level about 5 minutes after
LOCATIONS a fully warmed engine is shut off. Checking the oil
level while the vehicle is on level ground will
DESCRIPTION improve the accuracy of the oil level reading. Add oil
The fluid check/fill point locations are located in only when the level is at or below the ADD or MIN
each applicable service manual section. mark.
• Check the windshield washer solvent and add if
required.
LUBRICATION POINTS
Once a Month
DESCRIPTION • Check tire pressure and look for unusual wear
Lubrication point locations are located in each or damage.
applicable Sections. • Inspect the battery and clean and tighten the
terminals as required.
• Check the fluid levels of coolant reservoir, brake
MAINTENANCE SCHEDULES master cylinder and transmission, add as needed.
• Check all lights and all other electrical items for
correct operation.
DESCRIPTION
At Each Oil Change
DESCRIPTION • Change the engine oil filter.
There are two maintenance schedules that show • Inspect the exhaust system.
the required service for your vehicle. • Inspect the brake hoses.
First is Schedule “B”. It is for vehicles that are • Inspect the CV joints and front suspension com-
operated under the conditions that are listed below ponents.
and at the beginning of the schedule. • Check the automatic transmission fluid level.
• Day or night temperatures are below 32° F (0° • Check the coolant level, hoses, and clamps.
C).
• Stop and go driving. SCHEDULE B
• Extensive engine idling. Follow schedule “B” if you usually operate your
• Driving in dusty conditions. vehicle under one or more of the following conditions.
• Short trips of less than 10 miles (16 km). Change the automatic transmission fluid and filter
• More than 50% of your driving is at sustained every 60,000 miles (96 000 km) if the vehicle is usu-
high speeds during hot weather, above 90° F (32° C). ally operated under one or more of the conditions
• Trailer towing.L marked with an L.
• Taxi, police, or delivery service (commercial ser- • Day or night temperatures are below 32° F (0°
vice).L C).
• Off-road or desert operation. • Stop and go driving.
• Extensive engine idling.
NOTE: Most vehicles are operated under the condi-
• Driving in dusty conditions.
tions listed for Schedule (B(.
• Short trips of less than 10 miles (16 km).
Second is Schedule “A”. It is for vehicles that are • More than 50% of your driving is at sustained
not operated under any of the conditions listed under high speeds during hot weather, above 90° F (32° C).
Schedule 9B9. • Trailer towing.L
Use the schedule that best describes your driving • Taxi, police, or delivery service (commercial ser-
conditions. Where time and mileage are listed, follow vice).L
the interval that occurs first. • Off-road or desert operation.

CAUTION: Failure to perform the required mainte-

nance items may result in damage to the vehicle.
Dodge Caravan 2002 2007 Factory Service Manual
Full download: http://manualplace.com/download/dodge-caravan-2002-2007-factory-service-manual/
0-8 LUBRICATION & MAINTENANCE RS
MAINTENANCE SCHEDULES (Continued)

Miles 3, 000 6, 000 9, 000 12, 000 15, 000 18, 000
(Kilometers) (5 000 ) (10 000 ) (14 000) (19 000) (24 000) (29 000)
Change engine oil and engine X X X X X X
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner X X X X X
filter, replace if necessary. *
Replace the engine air X
cleaner filter. *
Replace the air conditioning X
filter.

Miles 21, 000 24, 000 27, 000 30, 000 33, 000 36, 000
(Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)
Change engine oil and engine X X X X X X
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner X X X X X
filter, replace if necessary. *
Replace the engine air X
cleaner filter.
Inspect the tie rod ends and X
boot seals.
Inspect the PCV valveand X
replace as necessary.*
Replace the air conditioning X X
filter.

Miles 39, 000 42, 000 45, 000 48, 000 51, 000 54, 000
(Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)
Change engine oil and engine X X X X X X
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner X X X X X
filter, replace if necessary. *
Replace the engine air X
cleaner filter. *
Replace the air conditioning X
filter.

This is the cut pages sample. Download all 2338 page(s) at: ManualPlace.com