Dodge Caravan (2008 year). 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 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.

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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
filler cap message will be displayed in the instrument
cluster. Tighten the gas cap until a

9clicking9 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. 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 this 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 not be ready if the 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, the vehicle may fail the test.

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This vehicle has a simple ignition key-actuated test,
which you can use prior to going to the test station. To
check if this vehicle’s OBD II system is ready, you must
do the following:

1. Insert the 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 the ignition 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 key or start the engine. This means that the
vehicle’s OBD II 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 the vehicle’s OBD II
system is ready, and you can proceed to the I/M
station.

If the OBD II system is not ready, you should see an
authorized dealer or repair facility. If this vehicle was
recently serviced or had a battery failure or replacement,
you may need to do nothing more than drive the vehicle
as you normally would in order for the OBD II system to
update. A recheck with the above test routine may then
indicate that the system is now ready.

Regardless of whether the vehicle’s OBD II system is
ready or not ready, if the MIL is illuminated during
normal vehicle operation, you should have the vehicle

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439

serviced before going to the I/M station. The I/M station
can fail the vehicle because the MIL is on with the engine
running.

REPLACEMENT PARTS

Use of genuine Mopar

t parts 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

t parts for maintenance

and repairs will not be covered by the manufacturer’s
warranty.

AUTHORIZED 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 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.

440

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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.

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 five
minutes after a fully warmed engine is shut off or before
starting the engine after it has sat overnight.

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441

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.

Change Engine Oil
The oil change indicator system will remind you that it is
time to take your vehicle in for scheduled maintenance.
Refer to “Maintenance Schedule” in Section 8 of this
manual for information on this system.

NOTE:

Under no circumstances should oil change

intervals exceed 6,000 miles (10 000 km) or six months,
whichever occurs first.

Engine Oil Selection
For best performance and maximum protection under all
types of operating conditions, the manufacturer only

Engine Oil Dipstick

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MAINTAINING YOUR VEHICLE

recommends engine oils that are API certified and meet
the requirements of DaimlerChrysler Material Standard
MS-6395.

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) — 3.3L & 3.8L
Gasoline Engines
SAE 5W-20 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) — 4.0 Liter
Engines
SAE 10W-30

engine oil is preferred for all operating

temperatures. The engine oil filler cap also shows the
recommended engine oil viscosity for your vehicle.

Lubricants which DO NOT have both, the engine oil
certification mark and the correct SAE viscosity grade
number should not be used.

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443

Synthetic Engine Oils
You may use synthetic engine oils provided the recom-
mended oil quality requirements are met, and the recom-
mended maintenance intervals for oil and filter changes
are followed.

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 its
performance may be impaired by supplemental addi-
tives.

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 authorized 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

t Engine Oil Filters are a high quality oil

filter and are recommended.

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MAINTAINING YOUR VEHICLE

DRIVE BELT

At the mileage indicated in the maintenance schedule,
replace the drive belt with a new drive belt.

NOTE:

The drive belt must be routed correctly to ensure

proper drive function.

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 Fluids, Lubricants and Genuine Parts for
correct spark plug type.

ENGINE AIR CLEANER

Refer to the “Maintenance Schedule” in Section 8 of this
manual for engine air cleaner filter maintenance inter-
vals.

NOTE:

Be sure to follow the “dusty or off-road condi-

tions” maintenance interval if applicable.

WARNING!

The air induction system (air cleaner, hoses, etc.) can
provide a measure of protection in the case of engine
backfire. Do not remove the air induction system (air
cleaner, hoses, etc.) 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 induction system (air cleaner,
hoses, etc.) removed. Failure to do so can result in
serious personal injury.

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445

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.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being assessed
against you.

446

MAINTAINING YOUR VEHICLE

WARNING!

A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.

In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut off and the
vehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer’s specifications, should be ob-
tained immediately.

To minimize the possibility of catalyst damage:

• Do not shut off the engine or interrupt the ignition

when the transaxle is in gear and the vehicle is in
motion.

• Do not try to start engine by pushing or towing the

vehicle.

• Do not idle the engine with any spark plug wires

disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.

Exhaust System
The best protection against carbon monoxide entry into
the vehicle body is a properly maintained engine exhaust
system.

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447

Whenever a change is noticed in the sound of the exhaust
system, when exhaust fumes can be detected inside the
vehicle, or when the underside or rear of the vehicle is
damaged, have a competent mechanic inspect the com-
plete exhaust system and adjacent body areas for broken,
damaged, deteriorated, or mispositioned parts. Open
seams or loose connections could permit exhaust fumes
to seep into the passenger compartment. In addition,
inspect the exhaust system each time the vehicle is raised
for lubrication or oil change. Replace as required.

WARNING!

Exhaust gases can injure or kill. They contain carbon
monoxide (CO) which is colorless and odorless.
Breathing it can make you unconscious and can
eventually poison you. To avoid breathing CO, refer
to “Exhaust Gas” in the Safety Tips section of this
manual.

MAINTENANCE-FREE BATTERY

The top of the MAINTENANCE-FREE battery is perma-
nently sealed. You will never have to add water, nor is
periodic maintenance required.

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MAINTAINING YOUR VEHICLE

WARNING!

• Battery fluid is a corrosive acid solution and can

burn or even blind you. Don’t allow battery fluid
to contact your eyes, skin or clothing. Don’t lean
over a battery when attaching clamps. If acid
splashes in eyes or on skin, flush the area imme-
diately with large amounts of water.

• Battery gas is flammable and explosive. Keep

flame or sparks away from the battery. Don’t use a
booster battery or any other booster source with an
output greater than 12 volts. Don’t allow cable
clamps to touch each other.

• Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.

CAUTION!

• It is essential when replacing the cables on the

battery that the positive cable is attached to the
positive post and the negative cable is attached to
the negative post. Battery posts are marked posi-
tive (+) and negative (-) and identified on the
battery case. Cable clamps should be tight on the
terminal posts and free of corrosion.

• If a “fast charger” is used while the battery is in

the vehicle, disconnect both vehicle battery cables
before connecting the charger to battery. Do not
use a “fast charger” to provide starting voltage.

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449

AIR CONDITIONER MAINTENANCE

For best possible performance, your air conditioner
should be checked and serviced by an authorized dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a system
performance check. Drive belt tension should also be
checked at this time.

WARNING!

• Use only refrigerants and compressor lubricants

approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer to
Section 3 of the Warranty Information book for
further warranty information.

• The air conditioning system contains refrigerant

under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.

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Refrigerant Recovery And Recycling
R-134a Air Conditioning Refrigerant is a hydrofluoro-
carbon (HFC) that is endorsed by the Environmental
Protection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by an authorized dealer or other an
authorized service facility using recovery and recycling
equipment.

NOTE:

Use only manufacturer approved A/C System

Sealers, Stop Leak Products, Seal Conditioners, Compres-
sor Oil, or Refrigerants.

A/C Air Filter — If Equipped
Refer to the “Maintenance Schedule” in Section 8 of this
manual for A/C Air Filter service intervals.

WARNING!

Do not remove the A/C Air Filter while the blower is
operating or personal injury may result.

The A/C Air Filter is located in the fresh air inlet behind
the glove box. Perform the following procedure to re-
place the filter:

1. Open the glove box and remove all contents.

2. Push in on the sides of the glove box and lower the
door.

3. Pivot the glove box downward.

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Dodge Caravan (2008 year). Manual - part 28