Dodge Caravan (2008 year). Manual

4. Disengage the two retaining tabs that secure the filter
cover to the HVAC housing and remove the cover.

5. Remove the A/C Air Filter by pulling it straight out of
the housing.

6. Install the A/C Air Filter with the arrow on the filter
pointing toward the floor. When installing the filter
cover, make sure the retaining tabs fully engage the
cover.

CAUTION!

The A/C Air Filter is labeled with an arrow to
indicate airflow direction through the filter. Failure
to properly install the filter will result in the need to
replace it more often.

7. Rotate the glove box door back into position.

POWER STEERING — FLUID CHECK

Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are

A/C Air Filter Replacement

452

MAINTAINING YOUR VEHICLE

apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through an autho-
rized DaimlerChrysler Dealership.

WARNING!

Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to ensure accurate fluid level reading. Do
not overfill. Use only manufacturer’s recommended
power steering fluid.

If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Fluids, Lubricants, and Genuine Parts
for correct fluid type.

FRONT SUSPENSION — BALL JOINTS

The front suspension ball joints are permanently sealed.
No regular maintenance is required for these compo-
nents.

STEERING SHAFT SEAL

The steering shaft seal, at the point where the shaft passes
through the bulkhead, is lubricated when it is installed. If
the seal becomes noisy when the steering shaft is turned,
it should be lubricated with a multipurpose grease.
Mopar

t multipurpose lubricant is recommended.

Steering Linkage
The tie rod end ball joints are permanently lubricated and
do not require periodic maintenance.

MAINTAINING YOUR VEHICLE

453

DRIVE SHAFT UNIVERSAL JOINTS

Your vehicle has constant velocity universal joints. Peri-
odic lubrication of these joints is not required. However,
the joint boots should be inspected for external leakage or
damage when other maintenance is performed. If leakage
or damage is evident, the universal joint boot and grease
should be replaced immediately.

Continued operation could result in failure of the univer-
sal joint due to water and dirt contamination of the
grease. This would require complete replacement of the
joint assembly.

BODY LUBRICATION

Locks and all body pivot points, including such items as
seat tracks, doors, liftgate, sliding doors and hood hinges,
should be lubricated periodically to assure quiet, easy
operation and to protect against rust and wear. Prior to
the application of any lubricant, the parts concerned
should be wiped clean to remove dust and grit; after

lubricating excess oil and grease should be removed.
Particular attention should also be given to hood latching
components to ensure proper function. When performing
other underhood services, the hood latch, release mecha-
nism and safety catch should be cleaned and lubricated.

The external lock cylinders should be lubricated twice a
year, preferably in the Fall and Spring. Apply a small
amount of a high quality lubricant such as Mopar

t Lock

Cylinder Lubricant directly into the lock cylinder.

WINDSHIELD WIPER BLADES

The rubber edges of the wiper blades and the windshield
should be cleaned periodically with a sponge or soft cloth
and a mild nonabrasive cleaner. This will remove accu-
mulations of salt or road film.

Operation of the wipers on dry glass for long periods
may cause deterioration of the wiper blades. Always use
washer fluid when using the wipers to remove salt or dirt
from a dry windshield.

454

MAINTAINING YOUR VEHICLE

Avoid using the wiper blades to remove frost or ice from
the windshield. Keep the blade rubber out of contact with
petroleum products such as engine oil, gasoline, etc.

Windshield and Rear Window Washers
The fluid reservoir for the windshield washers and the
rear window washer is shared. It is located in the engine
compartment and should be checked for fluid level at
regular intervals. Fill the reservoir with windshield
washer solvent (not radiator antifreeze) and operate the
system for a few seconds to flush out the residual water.

The washer fluid reservoir will hold a full gallon of fluid
when the Low Washer Fluid Light illuminates.

WARNING!

Commercially available windshield washer solvents
are flammable. They could ignite and burn you. Care
must be exercised when filling or working around
the washer solution.

After the engine has warmed, operate the defroster for a
few minutes to reduce the possibility of smearing or
freezing the fluid on the cold windshield. Mopar

t All

Weather Windshield Washer Solution, used with water as
directed on the container, aids cleaning action, reduces
the freezing point to avoid line clogging, and is not
harmful to paint or trim.

MAINTAINING YOUR VEHICLE

455

COOLING SYSTEM

WARNING!

• When working near the radiator cooling fan, dis-

connect the fan motor lead or turn the ignition
switch to the OFF position. The fan is temperature
controlled and can start at anytime the ignition
switch is in the ON position.

• You or others can be badly burned by hot coolant

or steam from your radiator. If you see or hear
steam coming from under the hood, don’t open the
hood until the radiator has had time to cool. Never
try to open a cooling system pressure cap when the
radiator is hot.

Coolant Checks
Check the engine coolant (antifreeze) protection every 12
months (before the onset of freezing weather, where
applicable). If coolant is dirty or rusty in appearance, the
system should be drained, flushed and refilled with fresh
coolant. Check the front of the A/C condenser for any
accumulation of bugs, leaves, etc. If dirty, clean by gently
spraying water from a garden hose vertically down the
face of the condenser.

Check the coolant recovery bottle tubing for brittle rub-
ber, cracking, tears, cuts and tightness of the connection
at the bottle and radiator. Inspect the entire system for
leaks.

With the engine at normal operating temperature (but
not running), check the cooling system pressure cap for
proper vacuum sealing by draining a small amount of
coolant from the radiator drain cock. If the cap is sealing
properly, the engine coolant (antifreeze) will begin to

456

MAINTAINING YOUR VEHICLE

drain from the coolant recovery bottle. DO NOT RE-
MOVE THE COOLANT PRESSURE CAP WHEN THE
COOLING SYSTEM IS HOT.

Cooling System — Drain, Flush and Refill
The system should be drained, flushed, and refilled at the
intervals shown in the “Maintenance Schedule” in Sec-
tion 8 of this manual.

If the solution is dirty or contains a considerable amount
of sediment, clean and flush with a reliable cooling
system cleaner. Follow with a thorough rinsing to remove
all deposits and chemicals. Properly dispose of old
antifreeze solution.

Selection Of Coolant
Use only the manufacturer’s recommended coolant, refer
to Fluids, Lubricants and Genuine Parts for correct
coolant type.

CAUTION!

Mixing of coolants other than specified Hybrid Or-
ganic Additive Technology (HOAT) engine coolants,
may result in engine damage and may decrease
corrosion protection. If a non-HOAT coolant is intro-
duced into the cooling system in an emergency, it
should be replaced with the specified coolant as soon
as possible.

Do not use plain water alone or alcohol base engine
coolant (antifreeze) products. Do not use additional
rust inhibitors or anti-rust products, as they may not
be compatible with the radiator engine coolant and
may plug the radiator.

This vehicle has not been designed for use with
Propylene Glycol based coolants. Use of Propylene
Glycol based coolants is not recommended.

MAINTAINING YOUR VEHICLE

457

Adding Coolant
Your vehicle has been built with an improved engine
coolant that allows extended maintenance intervals. This
coolant can be used up to five years or 102,000 mi (170
000 km) before replacement. To prevent reducing this
extended maintenance period, it is important that you
use the same coolant throughout the life of your vehicle.
Please review these recommendations for using Hybrid
Organic Additive Technology (HOAT) coolant.

When adding coolant, a minimum solution of 50% rec-
ommended Mopar

t Antifreeze/ Coolant Five Year/

100,000 mi (160 934 km) Formula HOAT (Hybrid Organic
Additive Technology), or equivalent, in water should be
used. Use higher concentrations (not to exceed 70%) if
temperatures below

234°F (237°C ) are anticipated.

Use only high purity water such as distilled or deionized
water when mixing the water/engine coolant solution.

The use of lower quality water will reduce the amount of
corrosion protection in the engine cooling system.

Please note that it is the owner’s responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated.

NOTE:

Mixing coolant types will decrease the life of the

engine coolant and will require more frequent coolant
changes.

Cooling System Pressure Cap
The cap must be fully tightened to prevent loss of
coolant, and to ensure that coolant will return to the
radiator from the coolant recovery bottle.

The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.

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MAINTAINING YOUR VEHICLE

WARNING!

• The warning words “DO NOT OPEN HOT” on

the cooling system pressure cap are a safety pre-
caution. Never add coolant when the engine is
overheated. Do not loosen or remove the cap to
cool an overheated engine. Heat causes pressure to
build up in the cooling system. To prevent scald-
ing or injury, do not remove the pressure cap while
the system is hot or under pressure.

• Do not use a pressure cap other than the one

specified for your vehicle. Personal injury or en-
gine damage may result.

Disposal of Used Coolant
Used ethylene glycol-based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your

community. To prevent ingestion by animals or children
do not store ethylene glycol-based engine coolant in open
containers or allow it to remain in puddles on the
ground. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.

Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine cold, the level of the coolant in the coolant
recovery bottle should be between the ranges indicated
on the bottle.

The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.

MAINTAINING YOUR VEHICLE

459

When additional coolant is needed to maintain the
proper level, it should be added to the coolant bottle. Do
not overfill.

Points To Remember

NOTE:

When the vehicle is stopped after a few miles (a

few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high
humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot coolant to
enter the radiator.

If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.

• Do not overfill the coolant recovery bottle.

• Check coolant freeze point in the radiator and in the

coolant recovery bottle. If antifreeze needs to be
added, contents of coolant recovery bottle must also be
protected against freezing.

• If frequent coolant additions are required, or if the

level in the coolant recovery bottle does not drop when
the engine cools, the cooling system should be pres-
sure tested for leaks.

• Maintain coolant concentration at 50% HOAT engine

coolant (minimum) and distilled water for proper
corrosion protection of your engine which contains
aluminum components.

• Make sure that the radiator and coolant recovery

bottle overflow hoses are not kinked or obstructed.

• Keep the front of the radiator clean. If your vehicle is

equipped with air conditioning, keep the front of the
condenser clean, also.

460

MAINTAINING YOUR VEHICLE

• Do not change the thermostat for summer or winter

operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.

HOSES AND VACUUM/VAPOR HARNESSES

Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.

Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.

Ensure nylon tubing in these areas has not melted or
collapsed.

Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.

Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.

FUEL SYSTEM CONNECTIONS

The Electronic Fuel Injection high-pressure fuel system’s
hoses and quick connect fittings have unique material
characteristics that provide adequate sealing and resist
attack by deteriorated gasoline.

You are urged to use only the manufacture specified
hoses with quick connect fittings, or their equivalent in
material and specification, in any fuel system servicing. It
is mandatory to replace any damaged hoses or quick
connect fittings that have been removed during service.
Care should be taken in installing quick connect fittings
to ensure they are properly installed and fully connected.
See your authorized dealer for service.

MAINTAINING YOUR VEHICLE

461

BRAKES

In order to assure brake system performance, all brake
system components should be inspected periodically.
Suggested service intervals can be found in the Mainte-
nance Schedules.

WARNING!

Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You wouldn’t have your full
braking capacity in an emergency.

Brake And Power Steering Hoses
When the vehicle is serviced for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
heat and mechanical damage. Hard and brittle rubber,

cracking, tears, cuts, abrasion, and excessive swelling
indicate deterioration of the rubber. Particular attention
should be made to examining those hose surfaces nearest
to high heat sources, such as the exhaust manifold.

Ensure nylon tubing in these areas has not melted or
collapsed.

Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.

NOTE:

Often, fluid such as oil, power steering fluid,

and brake fluid are used during assembly plant opera-
tions to facilitate the assembly of hoses to couplings.
Therefore, oil wetness at the hose-coupling area is not
necessarily an indication of leakage. Actual dripping of
hot fluid when systems are under pressure (during
vehicle operation), should be noted before hose is re-
placed based on leakage.

462

MAINTAINING YOUR VEHICLE

NOTE:

Inspection of brake hoses should be performed

whenever the brake system is serviced and every engine
oil change. Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If there is any evidence
of cracking, scuffing, or worn spots, the hose should be
replaced immediately! Eventual deterioration of the hose
can take place resulting in a possibility of a burst failure.

WARNING!

Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.

Master Cylinder — Brake Fluid Level Check
The fluid level in the master cylinder should be checked
when performing underhood services, or immediately if
the brake system warning light indicates system failure.

Clean the top of the master cylinder area before removing
the cap. Add fluid to bring the level up to the top of the
“FULL” mark on the side of the master cylinder reservoir.

Overfilling of fluid is not recommended because it may
cause leaking in the system.

Add enough fluid to bring the level up to the require-
ments described on the brake fluid reservoir. With disc
brakes, fluid level can be expected to fall as the brake
pads wear. However, low fluid level may be caused by a
leak and a checkup may be needed.

Use only manufacturer’s recommended brake fluid, refer
to Fluids, Lubricants and Genuine Parts for correct fluid
type.

MAINTAINING YOUR VEHICLE

463

WARNING!

• Overfilling the brake fluid reservoir can result in

spilling brake fluid on hot engine parts and the
brake fluid catching fire.

• Use of a brake fluid that has a lower initial boiling

point than the recommended MOPAR

t DOT 3

product or a brake fluid that is unidentified as to
FMVSS specification may result in sudden brake
failure during hard prolonged braking. You could
have an accident.

Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.

CAUTION!

Do not allow petroleum base fluid to contaminate the
brake fluid — all brake seal components could be
damaged causing partial or complete brake failure.

AUTOMATIC TRANSAXLE

The automatic transaxle and differential assembly are
contained within a single housing.

The fluid level in the automatic transaxle should be
checked whenever the vehicle is serviced. Operation with
an improper fluid level will greatly reduce the life of the
transaxle and the fluid.

All Four–Speed automatic transaxles are equipped with a
conventional filler tube and dipstick. If fluid is added, it
should be added through the filler tube.

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MAINTAINING YOUR VEHICLE

All six speed transaxles are equipped with a capped
dipstick tube, it is sealed and should not be tampered
with. Your authorized dealer has the necessary tools to
ensure that the fluid level is set properly.

Selection of Lubricant
It is important that the proper lubricant is used in the
transaxle to assure optimum transaxle performance. Use
only manufacturer’s recommended transaxle fluid; refer
to Fluids, Lubricants and Genuine Parts for correct fluid
type. It is important that the transaxle fluid be main-
tained at the prescribed level using the recommended
fluid. No chemical flushes should be used in any trans-
axle; only the approved lubricant may be used.

CAUTION!

Using a transaxle fluid other than the manufacturer’s
recommended fluid may cause deterioration in trans-
axle shift quality and/or torque converter shudder.
Using a transaxle fluid other than the manufacturer’s
recommended fluid will result in more frequent
fluid and filter changes. Refer to Fluids, Lubricants
and Genuine Parts for correct fluid type.

Fluid Level Check — 3.8L and 4.0L Engines with
Six-Speed Automatic Transaxle — If Equipped
The Six-Speed automatic transaxle is a sealed unit and
has no dipstick. See your authorized dealer to have the
transaxle fluid checked or serviced.

MAINTAINING YOUR VEHICLE

465

Fluid Level Check — 3.3L Engine with Four-Speed
Automatic Transaxle — If Equipped
The dipstick is located just behind the radiator, lower
right side.

To properly check the automatic transaxle fluid level, the
following procedure must be used:

1. The vehicle must be on level ground.

2. The engine should be running at curb idle speed for a
minimum of 60 seconds.

3. Fully apply parking brake.

4. Place the gear selector lever momentarily in each gear
position ending with the lever in PARK. Wipe the area
around the dipstick clean to eliminate the possibility of
dirt entering the transaxle.

5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180°F (82°C), which
is the normal operating temperature after the vehicle has
been driven at least 15 miles (24 km). The fluid cannot be
comfortably held between the finger tips. Cold is when
the fluid is below 80°F (27°C).

6. Wipe the dipstick clean and reinsert until seated.
Remove dipstick and note reading.

a. If the fluid is hot, the reading should be in the
crosshatched area marked “HOT” (between the upper
two holes in the dipstick).

b. If the fluid is cold, the fluid level should be between
the lower two holes in the area marked “COLD”.

4 Speed ATX Diptstick

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MAINTAINING YOUR VEHICLE

If the fluid level indicates low, add sufficient fluid to
bring to the proper level.

CAUTION!

Do not overfill. Dirt and water in the transaxle can
cause serious damage. To prevent dirt and water from
entering the transaxle after checking or replenishing
fluid, make certain that the dipstick cap is reseated
properly.

Fluid and Filter Changes
Refer to the “Maintenance Schedule” in Section 8 of this
manual for the recommended transaxle fluid and filter
change intervals.

If the transaxle is disassembled for any reason, the fluid
and filter should be changed.

Special Additives
Automatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transaxle. The only exception to this policy is
the use of special dyes to aid in detecting fluid leaks. In
addition, avoid using transaxle sealers as they may
adversely affect seals.

FRONT AND REAR WHEEL BEARINGS

Front and rear wheel bearings are permanently sealed.
No regular maintenance is required for these compo-
nents.

APPEARANCE CARE AND PROTECTION FROM
CORROSION

Protection of Body and Paint from Corrosion
Vehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on

MAINTAINING YOUR VEHICLE

467

Dodge Caravan (2008 year). Manual - part 29