2004 Dodge Caravan Owners Manual

If necessary, add fluid to restore to the proper indicated level. With a clean cloth, wipe any spilled fluid from all surfaces. Refer to Recommended 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. Use only manufacturers recom- mended lubricant, refer to Recommended Fluids, Lubri- cants and Genuine Parts for correct lubricant type.

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

MAINTAINING YOUR VEHICLE 315

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 insure 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 Mopart Lock Cylinder Lubricant directly into the lock cylinder.

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.

316 MAINTAINING YOUR VEHICLE

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. 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

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

MAINTAINING YOUR VEHICLE 317

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, fol- low the preceding safety tips.

318 MAINTAINING YOUR VEHICLE

Cooling System

Inspection

WARNING!

† When working near the radiator cooling fan, turn the ignition key to the OFF position. The fan is temperature controlled and can start at any time when the ignition key 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 Coolant protection checks should be made every 12
months (prior to 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 removing the upper grill support and 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 coolant pressure cap for proper vacuum sealing by draining a small amount of coolant

from the radiator drain cock. If the cap is sealing prop- erly, the coolant will begin to drain from the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT. Cooling System — Drain, Flush and Refill At the intervals shown in the maintenance schedules, the system should be drained, flushed and refilled. 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 manufacturers recommended coolant, refer to Recommended Fluids, Lubricants and Genuine Parts for correct coolant type.

MAINTAINING YOUR VEHICLE 319

CAUTION!

† Mixing of coolants other than specified (non- HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. If a non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the speci- fied coolant as soon as possible. † Do not use plain water alone or alcohol base antifreeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. † This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propy- lene Glycol based coolants is not recommended.

320 MAINTAINING YOUR VEHICLE

Adding Coolant When adding coolant, or refilling the system, a minimum of 50% solution of ethylene glycol antifreeze coolant in water should be used. Higher concentrations (not to exceed 70%) are required if temperatures below 237°F (238°C) are anticipated. Use only high purity water such as distilled or deionized water when mixing the water/antifreeze 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.

Coolant Pressure Cap The coolant pressure cap must be fully tightened to prevent loss of coolant, and to insure that coolant will return to the radiator from the coolant recovery bottle. The coolant pressure cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.

WARNING!

The warning words “DO NOT OPEN HOT” on the coolant pressure cap are a safety precaution. Never add coolant to the radiator when the engine is over- heated. Do not loosen or remove the coolant pressure cap to cool an overheated engine. Heat causes pres- sure to build up in the cooling system. To prevent scalding or injury, do not remove the coolant pressure cap while the system is hot or under pressure.

Disposal of Used Engine 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 recovery bottle provides a quick visual method for determining that the coolant level is ad- equate. With the engine cold, the level of the coolant in the coolant recovery bottle should be between the “MAX” and “MIN” marks. The radiator normally re- mains completely full, so there is no need to remove the radiator cap except for checking coolant freeze point or replacement with new antifreeze coolant. Your service attendant should be advised of this. So long as the engine

MAINTAINING YOUR VEHICLE 321

operating temperature is satisfactory, the coolant recov- ery bottle need only be checked once a month. When additional coolant is needed to maintain the proper level, it should be added to the coolant recovery bottle. Do not overfill. Points to Remember NOTE: When the vehicle is stopped after a few miles 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 accumulat- ing on the radiator and being vaporized when the thermostat opens, allowing hot water to enter the radia- tor. 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.

322 MAINTAINING YOUR VEHICLE

† 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% ethylene glycol antifreeze (minimum) in 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.

† 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 cooling performance. † Increasing engine speed at idle does not reduce cool- ant temperature! Put transmission in NEUTRAL and let engine idle at normal engine idle speed.

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.

Insure 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. 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.

MAINTAINING YOUR VEHICLE 323

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.

324 MAINTAINING YOUR VEHICLE

Insure 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. Inspection of brake hoses should be performed NOTE: 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 — ABS Brakes 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 manufacturers recommended brake fluid, refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.

WARNING!

Use of brake fluid that may have a lower initial boiling point or unidentified as to specification, may result in sudden brake failure during hard pro- longed braking. You could have an accident.

MAINTAINING YOUR VEHICLE 325

WARNING!

Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire.

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.

326 MAINTAINING YOUR VEHICLE

Fuel System Hoses Electronic Fuel Injection high pressure fuel systems are designed with hoses and clamps which have unique material characteristics to provide adequate sealing and resist attack by deteriorated gasoline. You are urged to use only the manufacturers specified hoses and clamps, or their equivalent in material and specification, in any fuel system servicing. It is manda- tory to replace all clamps that have been loosened or removed during service. Care should be taken in install- ing new clamps to insure they are properly torqued. Automatic Transmission The automatic transmission and differential assembly are contained within a single housing. All automatic transmissions are equipped with a conven- tional filler tube and dipstick. If fluid is added, it should be added through the dipstick hole in the case.

The dipstick is located just behind the radiator, lower right side. Selection of Lubricant It is important that the proper lubricant is used in the transmission to assure optimum transmission perfor- mance. Use only manufacturers recommended transmis- sion fluid, refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluid.

CAUTION!

Using a transmission fluid other than the manufac- turers recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturers recommended fluid will result in more frequent fluid and filter changes. Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.

MAINTAINING YOUR VEHICLE 327

Procedure For Checking Fluid Level The fluid level in the automatic transmission should be checked whenever the vehicle is serviced. Operation with an improper fluid level will greatly reduce the life of the transmission and of the fluid. To properly check the automatic transmission 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 momentarily in each gear position ending with the lever in P (PARK). Wipe the area around the dipstick clean to eliminate the possibility of dirt entering the transmission.

328 MAINTAINING YOUR VEHICLE

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”.

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

CAUTION!

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

Fluid and Filter Changes Automatic transmission fluid should be changed on all transmissions as follows: Normal Usage — No change necessary Severe Usage (fluid and filter) — 60,000 miles (96 000 km) Severe Usage is defined as: † Police, taxi, limousine, commercial type operation, or trailer towing where the vehicle is driven regularly for more than 45 minutes of continuous operation.

NOTE: Refer to Section 8 of this manual for Mainte- nance Schedules. If the transmission is disassembled for any reason, the fluid and filter should be changed. Special Additives Do not add any fluid additives to the transmission. The only exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided as they may adversely affect seals.

MAINTAINING YOUR VEHICLE 329

All Wheel Drive (AWD) Under normal operating conditions, periodic fluid level checks and lubricant changes for the Power Transfer Unit, Overrunning Clutch and Rear Carrier, are not required. However when the vehicle is serviced for other reasons, the exterior surface of these components should be inspected for evidence of fluid leaks. Confirmed leaks should be repaired as soon as possible. Power Transfer Unit The fluid should be maintained at the bottom of the filler hole opening. If it becomes necessary to add or replace the fluid, use only the manufacturers recommended fluid, refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. Overrunning Clutch The fluid should be maintained at the bottom of the filler hole opening. If it becomes necessary to add or replace the fluid, use only the manufacturers recommended

330 MAINTAINING YOUR VEHICLE

transmission fluid, refer to Recommended Fluids, Lubri- cants and Genuine Parts for correct fluid type. To assure performance, it is important that the proper lubricant be used. Rear Carrier The fluid should be maintained at the bottom of the filler hole opening. if it becomes necessary to add or replace the fluid, use only the manufacturers recommended fluid, refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. Fluid Changes The fluid should be changed as follows: Normal Usage Severe Usage

No Service Required

Power Transfer Unit Overrunning Clutch

Rear Carrier

15,000 miles (24 000 km) 22,500 miles (36 000 km) 22,500 miles (36 000 km)

Severe Usage is defined as: 1. More than 50% of vehicle operation in stop and go traffic where the vehicle is driven regularly for more than 45 minutes of continuous operation, such as in heavy city or in construction zone traffic, 2. Police, taxi, limousine, commercial type operation, or trailer towing where the vehicle is driven regularly for more than 45 minutes of continuous operation. 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

trees and road surfaces during other seasons, are highly corrosive to the metal in your vehicle. Outside parking, which exposes your vehicle to airborne contaminants, road surfaces on which the vehicle is operated, extreme hot or cold weather and other extreme conditions will have an adverse effect on paint, metal trim, and under- body protection. The following maintenance recommendations will enable you to obtain maximum benefit from the corrosion resistance built into your vehicle. What Causes Corrosion? Corrosion is the result of deterioration or removal of paint and protective coatings from your vehicle. The most common causes are: † Road salt, dirt and moisture accumulation. † Stone and gravel impact.

MAINTAINING YOUR VEHICLE 331

† Insects, tree sap and tar. † Salt in the air near seacoast localities. † Atmospheric fallout/industrial pollutants. Washing † Wash your vehicle regularly. Always wash your ve- hicle in the shade using a mild car wash soap, and rinse the panels completely with clear water. † If insects, tar or other similar deposits have accumu- † Use Mopar auto polish to remove road film and stains and to polish your vehicle. Take care never to scratch the paint. † Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.

lated on your vehicle, wash it as soon as possible.

332 MAINTAINING YOUR VEHICLE

CAUTION!

Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.

Special Care † If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month. † It is important that the drain holes in the lower edges of the doors, rocker panels and liftgate be kept clear and open. † If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner.

† If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating have your vehicle repaired as soon as possible. The cost of such repairs is considered the responsibil- ity of the owner. † All wheels and wheel trim, especially aluminum and chrome plated wheels should be cleaned regularly with mild soap and water to prevent corrosion. To remove heavy soil, select a nonabrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush or metal polishes. Only Mopar cleaners are recommended. Do not use oven cleaner. Avoid auto- matic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective fin- ish. † If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed.

mud or stone shields behind each wheel.

† If a lot of driving is done on gravel roads, consider † Use Mopar touch up paint on scratches as soon as possible. Your dealer has touch up paint to match the color of your vehicle.

Interior Care Use Mopar Fabric Cleaner to clean fabric upholstery and carpeting. Use Mopar Vinyl Cleaner to clean vinyl upholstery and trim. Mopar Total Clean is specifically recommended for leather upholstery. Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth

MAINTAINING YOUR VEHICLE 333

and Mopar Total Clean. Care should be taken to avoid soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, deter- gents, or ammonia based cleaners to clean your leather upholstery. Application of a leather conditioner is not required to maintain the original condition.

WARNING!

Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.

Glass Surfaces All glass surfaces should be cleaned on a regular basis with any commercial household-type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning inside rear windows equipped with electric

334 MAINTAINING YOUR VEHICLE

defrosters or windshields equipped with a windshield wiper de-icer. Do not use scrapers or other sharp instru- ments which may scratch the elements. When cleaning the rear view mirror, spray cleaner on the towel or rag that you are using. Do not spray cleaner directly on the mirror. Cleaning Plastic Instrument Cluster Lenses The lenses in front of the instruments in this vehicle are molded in clear plastic. When cleaning the lenses, care must be taken to avoid scratching the plastic. 1. Clean with a wet soft rag. A mild soap solution may be used, but do not use high alcohol content or abrasive cleaners. If soap is used, wipe clean with a clean damp rag. 2. Dry with a soft tissue.

Seat Belt Maintenance Do not bleach, dye or clean the belts with chemical solvents or abrasive cleaners. This will weaken the fabric. Sun damage will also weaken the fabric. If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the car to wash them. Replace the belts if they appear frayed or worn or if the buckles do not work properly. Cleaning The Instrument Panel and Underseat Cup Holders

Removal Remove the ash receiver from the convenience tray if there is a smoker’s package in your vehicle. With your index finger, locate the stop tab located at the rear of the convenience tray.

MAINTAINING YOUR VEHICLE 335

Cleaning Soak the drawer, with the drawer front facing up, in a mixture of medium hot tap water and one teaspoon of mild liquid dish soap. Let soak for approximately one hour. After one hour pull the drawer from the water and dip it back into the water about six times. This will loosen any remaining debris. Rinse the drawer thoroughly un- der warm running water. Shake the excess water from the drawer and dry the outer surfaces with a clean soft cloth. Let the drawer sit in a dish drainer overnight to allow the inside mechanism to dry. Installation Align the drawer so the plastic tracks on the drawer fit into the steel retainer in the instrument panel. Push the drawer forward. You may want to cycle the drawer open and closed a few times to ensure proper operation.

Press the stop tab, slide the entire drawer out and remove it from the instrument panel.

336 MAINTAINING YOUR VEHICLE

INTEGRATED POWER MODULE (IPM)

An Integrated Power Module is located in the engine compartment near the battery. This center contains fuses and relays. A label that identifies each component is printed on the inside of the cover.

CAUTION!

† When installing the Integrated Power Module cover, it is important to ensure the cover is prop- erly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. † When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse contin- ues to blow, it indicates a problem in the circuit that must be corrected.

The Heated Mirrors, Lower Instrument Panel Power Outlet and Removable Floor Console, when in the front position are fused with self resetting fuses that are only serviceable by an authorized dealer. The power seats are fused by a 30 Amp circuit breaker located under the driver’s seat. The Power Windows are fused by a 25 Amp circuit breaker located under the instrument panel near the steering column. If you experience temporary or permanent loss of these systems see your authorized dealer for service.

MAINTAINING YOUR VEHICLE 337

Module labeled Ignition-Off Draw (IOD).

VEHICLE STORAGE If you are leaving your vehicle dormant for more than 21
days you may want to take steps to protect your battery. You may: † Remove the 20 Amp mini fuse in the Integrated Power † Or, disconnect the negative cable from the battery. † Anytime you store your vehicle, or keep it out of service (i.e. vacation) for two weeks or more, run the air conditioning system at idle for about five minutes in the fresh air and high blower setting. This will insure adequate system lubrication to minimize the possibility of compressor damage when the system is started again.

LIGHT BULBS — Exterior Bulb Number Back-up, Tail, Stop, Turn Signal, & Sidemarker . . . 3057
Center High-Mounted Stop Light . . . . . . . . . . . . . 921
Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9040
Front Side marker, Park/Turn Signal . . . . . . . . . 3157A Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007
License. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

338 MAINTAINING YOUR VEHICLE

REPLACEMENT LIGHT BULBS

LIGHT BULBS — Interior Bulb Number Center & Rear Dome Light. . . . . . . . . . . . . . . . . . 578
Center & Rear Reading Lights . . . . . . . . . . . . . . . 578
Front Door Courtesy Light . . . . . . . . . . . . . . . . . . 578
Front Header Reading Lights (If Equipped) . . . . . . 578
Instrument Cluster Lights . . . . . . . . . . . . . . . . . PC74
Liftgate Light(s). . . . . . . . . . . . . . . . . . . . . . . . . . 578
Overhead Console Reading Lights . . . . . . . . . . PC579
Removable Console Light (If Equipped). . . . . . . . . 194
Visor Vanity Lights . . . . . . . . . . . . . . . . . . . . 6501966
NOTE: For lighted switches, see your dealer for replace- ment instructions. All of the interior bulbs are glass wedge base or glass cartridge types. Aluminum base bulbs are not approved and should not be used for replacement.

BULB REPLACEMENT

Headlights

1. Remove the three screws securing the headlight mod- ule.

MAINTAINING YOUR VEHICLE 339

3. Disconnect the electrical connector and replace the bulb.

2. Turn the bulb socket retaining ring counterclockwise.

340 MAINTAINING YOUR VEHICLE

CAUTION!

Do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol.

Front Park/Turn Signal and Sidemarker Lights

1. Remove the three screws securing the headlight mod- ule.

2. Twist the turn signal socket to remove from the headlight module and pull bulb from socket.

MAINTAINING YOUR VEHICLE 341

Front Fog Light

1. Reach behind the front fascia from under the vehicle. 2. Twist the front fog light bulb to remove from the fog light module. 3. Disconnect the electrical connector and replace the bulb.

CAUTION!

Do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol.

3. Replace bulb, reinstall socket and then reinstall the headlight module.

342 MAINTAINING YOUR VEHICLE

Rear Tail, Stop, Turn Signal, Side Marker and Back-up Lights

1. Raise the liftgate. 2. Remove the two light assembly push-in type fasteners.

4. Pull the bulb to remove it from the socket. 5. Replace the bulb, reinstall the socket, and reattach the light assembly.

3. Squeeze the socket assembly tabs to remove it from the housing.

Center High Mounted Stop Light (CHMSL)

1. Remove the two screws securing the CHMSL.

2. Twist the bulb socket to remove from the CHMSL housing. 3. Pull the bulb out of the socket. 4. Replace the bulb, reinstall the socket and reattach the CHMSL.

MAINTAINING YOUR VEHICLE 343

License Light 1. Remove the two lens assembly mounting screws. 2. Pull the bulb out of the socket. Replace the bulb and reattach the lens assembly.

FLUID CAPACITIES

Fuel (Approximate) Engine Oil-with filter 2.4 Liter Engine

3.3 & 3.8 Liter Engines

Cooling System *

U.S.

20 Gallons

Metric 76 Liters

5.0 qts 5.0 qts

4.7 Liters 4.7 Liters

11.4 qts 13.4 qts

2.4 Liter Engines

† 3.3 & 3.8 Liter Engines

10.7 Liters 12.6 Liters * Includes heater and coolant recovery bottle filled to MAX level. † * Add 2.9 quarts (2.8 liters) if equipped with a rear heater.

344 MAINTAINING YOUR VEHICLE

RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant

Engine Oil

Oil Filter 2.4 liter engines Oil Filter 3.3/3.8 liter engines Spark Plugs

Fuel Selection

Fluids, Lubricants and Genuine Parts Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or- ganic Additive Technology) Use API Certified, meeting material standard MS-6395, (GF-3). Refer to oil viscosity chart for correct SAE grade. Mopar 4105409 or equiv. Mopar 5281090 or equiv. Refer to the Vehicle Emission Control Information label in the engine com- partment. 87 Octaane

Chassis Component Automatic Transmission AWD Power Transfer Unit AWD Overrunning Clutch AWD Rear Carrier Brake Master Cylinder

Power Steering Reservoir

MAINTAINING YOUR VEHICLE 345

Fluids, Lubricants and Genuine Parts. Mopart ATF+4 Automatic Transmission Fluid. Mopart Gear Lubricant 75W-90. Mopart ATF+4 Automatic Transmission Fluid. Mopart Gear Lubricant 75W-90. Mopart DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not available, then DOT 4 or DOT 4+ is acceptable. Use only recommended brake fluids. Mopart ATF+4 Automatic Transmission Fluid.

MAINTENANCE SCHEDULES

CONTENTS

m Emission Control System Maintenance . . . . . . . . 348
m Maintenance Schedules . . . . . . . . . . . . . . . . . . . 348

N Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 351
N Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 363

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348 MAINTENANCE SCHEDULES

EMISSION CONTROL SYSTEM MAINTENANCE The “Scheduled” maintenance services, listed in bold type must be done at the times or mileages specified to assure the continued proper functioning of the emission control system. These, and all other maintenance services included in this manual, should be done to provide best vehicle performance and reliability. More frequent main- tenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving. Inspection and service also should be done any time a malfunction is suspected. NOTE: Maintenance, replacement, or repair of the emis- sion control devices and systems on your vehicle may be performed by any automotive repair establishment or individual using any automotive part which has been certified pursuant to U.S. EPA or, in the State of Califor- nia, California Air Resources Board regulations.

MAINTENANCE SCHEDULES There are two maintenance schedules that show the required service for your vehicle. First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. † Day or night temperatures are below 32° F (0° C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 10 miles (16 km). † More than 50% of your driving is at sustained high † Trailer towing.L

speeds during hot weather, above 90° F (32° C).

vice).L

† Taxi, police, or delivery service (commercial ser- † Off-road or desert operation. NOTE: Most vehicles are operated under the conditions listed for Schedule 9B9. Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Sched- ule 9B9. Use the schedule that best describes your driving condi- tions. Where time and mileage are listed, follow the interval that occurs first.

CAUTION!

Failure to perform the required maintenance items may result in damage to the vehicle.

MAINTENANCE SCHEDULES 349

At Each Stop for Fuel † Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accu- racy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. † Check the windshield washer solvent and add if

required.

damage.

Once a Month † Check tire pressure and look for unusual wear or † Inspect the battery and clean and tighten the terminals † Check the fluid levels of coolant reservoir, brake † Check all lights and all other electrical items for correct

master cylinder and transmission; add as needed.

as required.

operation.

350 MAINTENANCE SCHEDULES

At Each Oil Change † Change the engine oil filter. † Inspect the exhaust system. † Inspect the brake hoses. † Inspect the CV joints and front suspension compo-

nents.

† Check the automatic transmission fluid level. † Check the coolant level, hoses, and clamps. Tire Rotation † Rotate the tires at 6,000 miles (10 000 km).

SCHEDULE “B” Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. Change the automatic transmission fluid and filter every 60,000
miles (96 000 km) if the vehicle is usually operated under one or more of the conditions marked with an L. † Day or night temperatures are below 32° F (0° C). † Stop and go driving. † Extensive engine idling.

SCHEDULE “B” 351

speeds during hot weather, above 90° F (32° C).

† Driving in dusty conditions. † Short trips of less than 10 miles (16 km). † More than 50% of your driving is at sustained high † Trailer towing.L † Taxi, police, or delivery service (commercial ser- † Off-road or desert operation.

vice).L

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352 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter. * Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, replace if necessary. Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart) Replace the air conditioning filter.

3, 000
(5 000 )

6, 000
(10 000 )

9, 000
(14 000)

12, 000
(19 000)

15, 000
(24 000)

18, 000
(29 000)

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter. Replace the spark plugs 2.4 liter engines. Inspect the tie rod ends and boot seals. Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, replace if necessary. Inspect the PCV valve and replace as neces- sary.* Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart)

21, 000
(34 000)

24, 000
(38 000)

27, 000
(43 000)

30, 000
(48 000)

33, 000
(53 000)

36, 000
(58 000)

SCHEDULE “B” 353

354 SCHEDULE “B”

Miles (Kilometers) Change the All Wheel Drive (AWD) overrun- ning clutch and rear carrier fluid. (See the note at the end of this chart) Replace the air conditioning filter.

21, 000
(34 000)

24, 000
(38 000)

27, 000
(43 000)

30, 000
(48 000)

33, 000
(53 000)

36, 000
(58 000)

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter. * Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, replace if necessary. Change the All Wheel Drive power transfer unit fluid. (See the note at the end of this chart.) Change the All Wheel Drive (AWD) overrun- ning clutch and rear carrier fluid. (See note at the end of this chart) Replace the air conditioning filter.

39, 000
(62 000)

42, 000
(67 000)

45, 000
(72 000)

48, 000
(77 000)

51, 000
(82 000)

54, 000
(86 000)

SCHEDULE “B” 355

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356 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter. Replace the spark plugs on 2.4 liter engines. Replace the ignition cables on 2.4 liter en- gines. Inspect the tie rod ends and boot seals. Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, replace if necessary. Inspect the PCV valve and replace if neces- sary.*

57, 000
(91 000)

60, 000
(96 000)

63, 000
(101 000)

66, 000
(106 000)

69, 000
(110 000)

72, 000
(115 000)

Miles (Kilometers) Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, replace if necessary. Change the automatic transaxle fluid and fil- ter. Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart) Change the All Wheel Drive (AWD) overrun- ning clutch and rear carrier fluid. (See note at the end of this chart) Replace the air conditioning filter.

57, 000
(91 000)

60, 000
(96 000)

63, 000
(101 000)

66, 000
(106 000)

69, 000
(110 000)

72, 000
(115 000)

SCHEDULE “B” 357

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358 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter Replace the spark plugs on 3.3 liter and 3.8
liter engines. Replace the ignition cables on 3.3 liter and 3.8
liter engines. Replace the spark plugs on 2.4 liter engines. Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, replace if necessary. Inspect the tie rod ends and boot seals.

75, 000
(120 000)

78, 000
(125 000)

81, 000
(130 000)

84, 000
(134 000)

87, 000
(139 000)

90, 000
(144 000)

Miles (Kilometers) Inspect engine accessory drive belts on 3.3 li- ter and 3.8 liter engines, replace if necessary. ‡ Check the PCV valve and replace if necessary. Not required if previously changed.* Change the All Wheel Drive power transfer unit fluid. (See the note at the end of this chart.) Change the All Wheel Drive (AWD) overrun- ning clutch and rear carrier fluid. (See note at the end of this chart) Replace the engine timing belt on 2.4 liter engines. * Replace the air conditioning filter.

75, 000
(120 000)

78, 000
(125 000)

81, 000
(130 000)

84, 000
(134 000)

87, 000
(139 000)

90, 000
(144 000)

SCHEDULE “B” 359

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360 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter * Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, replace if necessary. Inspect engine accessory drive belts on 3.3 liter and 3.8 liter engines, replace if necessary. ‡ Change the All Wheel Drive (AWD) power transfer unit, overrunning clutch and rear car- rier fluid. (See note at the end of this chart) Flush and replace the engine coolant at 60
months or 100,000 miles. Replace the air conditioning filter.

93, 000
(149 000)

96, 000
(154 000)

99, 000
(158 000)

100, 000
(160 000)

102, 000
(163 000)

105, 000
(168 000)

Miles (Kilometers) Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if neces- sary. * Replace the engine air cleaner filter. Replace the spark plugs on 2.4 liter engines. Replace the ignition cables on 2.4 liter engines. Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the generator belt on 2.4 liter engines, re- place if necessary. Inspect engine accessory drive belts on 3.3 liter and 3.8 liter engines, replace if necessary. ‡ Inspect the tie rod ends and boot seals. Inspect the PCV valve and replace as necessary.* Change the automatic transaxle fluid and filter.

108, 000
(173 000)

111, 000
(178 000)

114, 000
(182 000)

117, 000
(187 000)

120, 000
(192 000)

SCHEDULE “B” 361

362 SCHEDULE “B”

Miles (Kilometers) Change the All Wheel Drive (AWD) power transfer unit fluid. (See note at the end of this chart) Replace the air conditioning filter. * This maintenance is recommended by the manufacture to the owner but is not required to maintain the emis- sions warranty. ‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all re- ceipts.

108, 000
(173 000)

111, 000
(178 000)

114, 000
(182 000)

117, 000
(187 000)

120, 000
(192 000)

NOTE: The AWD power transfer unit fluid and the AWD overrunning clutch/ rear carrier fluid must be changed at the intervals shown in schedule B if the vehicle is operated under any of the conditions noted by a diamond at the beginning of the schedule.

SCHEDULE “A” Miles (Kilometers) [Months] Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter. Replace the spark plugs on 2.4 liter engines. Inspect the tie rod ends and boot seals. Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Replace the air conditioning filter.

SCHEDULE “A” 363

6, 000
(10 000)

12, 000
(19 000)

18, 000
(29 000)

24, 000
(38 000 )

30, 000
(48 000)

36, 000
(58 000)

[6]

[12]

[18]

[24]

[36]

[30]

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364 SCHEDULE “A”

Miles (Kilometers) [Months] Change engine oil and engine oil filter. Inspect the brake linings. Inspect the engine air cleaner filter, replace if necessary. * Replace the engine air cleaner filter. Replace the spark plugs on 2.4 liter engines. Replace the ignition cables 2.4 liter engines. Inspect and adjust the power steering pump belt tension on 2.4 liter engines. Inspect the tie rod ends and boot seals. Inspect the generator belt on 2.4 liter engines, replace if necessary. Check the PCV valve and replace, if neces- sary.*

42, 000
(67 000)

48, 000
(77 000)

54, 000
(86 000)

60, 000
(96 000)

66, 000
(106 000)

72, 000
(115 000)

[48]

[54]

[42]

[66]

[72]

[60]

Miles (Kilometers) [Months] Inspect the serpentine drive belt on 3.3 liter and 3.8 liter engines, replace if necessary. ‡ Flush and replace the engine coolant at 60
months, regardless of mileage. Replace the air conditioning filter.

42, 000
(67 000)

[42]

48, 000
(77 000)

[48]

54, 000
(86 000)

[54]

SCHEDULE “A” 365

60, 000
(96 000)

66, 000
(106 000)

72, 000
(115 000)

[66]

[60]

[72]

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